BSBTC-01

BUILDING SERVICES BRANCH

TESTING AND COMMISSIONING

PROCEDURE NO. 1

FOR

AIR-CONDITIONING, REFRIGERATION,

VENTILATION AND CONTROL SYSTEMS

IN

GOVERNMENT BUILDINGS

HONG KONG




?
HONG KONG SPECIAL ADMINISTRATIVE REGION GOVERNMENT








Building Services Branch
Architectural Services Department
(2000 Edition)





BSBTC-01


COPYRIGHT


1. This Testing and Commissioning Procedure is solely compiled for use on Air-
conditioning, Refrigeration, Ventilation and Control Systems in Government Buildings of
the Hong Kong Special Administrative Region.

2. This Testing and Commissioning Procedure is copyrighted and all rights (including
subsequent amendment) are reserved.

3. It is hereby declared that the procedure contained therein may not be pertinent or
fully cover the Air-conditioning, Refrigeration, Ventilation and Control Systems carried
out by other Government Departments or private sectors. Prior consent by the Director of
Architectural Services must be obtained for adoption of this testing and commissioning
procedure for Air-conditioning, Refrigeration, Ventilation and Control Systems of other
nature or locations.


































BSBTC-01 I


TABLE OF CONTENT

Page

1. Introduction 1

2. General Requirements 1

3. Testing and Inspection 2

4. Statutory Inspection/Commissioning 3

5. Calibrated Equipment 93


Appendix A Page

Testing and Commissioning Certificate on Air-conditioning, Refrigeration,
Ventilation and Control Systems


Part 1 : Details of Project 1

Part 2 : Declaration 1

Part 3 : Items Inspected and Tested 2

3.1 The General Requirements as indicated in the T & C procedure
have been complied with.
2

3.2 Precommissioning Checks 2

3.3 Setting to Work & Balancing 2

3.4 Comments 6


Part 4 : Test Record attached to the Test Certificate 7

4.1 General 7

4.2 Packaged Water Chillers 7

4.3 Air-Cooled Condensing Sets 8

4.4 Cooling Towers 9

4.5 Pumps (Medium) 10

4.6 Air Handling Units 11

4.7 Heating Coils (Not included in Air Handling Unit) 13

BSBTC-01 II


TABLE OF CONTENT

Page

4.8 Ducts, Grilles, Diffusers etc. 13

4.9 Testing Equipment 14


Appendix B Page

Testing and Commissioning progress chart for Air-conditioning, Refrigeration,
Ventilation and Control Systems
1


Appendix C Page

Flow Chart for Testing and Commissioning Procedure on Air-
conditioning, Refrigeration, Ventilation and Control Systems
1

Figure 1 Example of Water Distribution System 2

Figure 2 Example of Air Distribution System 3

Figure 3 Example of Air Distribution Branch 3

Figure 4 Example of Low Velocity Supply Air System 4

Figure 5 Example of Air Flow Sheet 5

BSBTC-01 1

B.S.B. Testing and Commissioning Procedure No. 1
Air-conditioning, Refrigeration, Ventilation and Control Systems




1. Introduction

1.1 This procedure is intended to lay down the minimum testing and
commissioning requirements to be carried out by the Contractor on a new
Air-conditioning, Refrigeration, Ventilation and Control Systems upon
completion or on an existing Air-conditioning, Refrigeration, Ventilation
and Control Systems after a major alteration. Additional testing and
commissioning (T & C) requirements may be proposed by the Contractor
as appropriate and agreed by the Project Building Services Engineer
(PBSE), e.g. for special equipment supplied and/or installed by the
Contractor.

1.2 This procedure is also written to facilitate the PBSE and Project Building
Services Inspector (PBSI) in carrying out the following aspects of work
with respect to T & C.

(i) To vet and approve the T & C procedures proposed and submitted by
the Contractor.

(ii) To witness those T & C procedures as specified.

(iii) To receive the T & C certificate and other supporting data.

2. General Requirements

2.1 The Contractor shall submit the T&C procedures to the PBSE for approval.
The submission shall be made at least one month before the
commencement of T&C.

2.2 Where tests are required to be witnessed by the PBSE/PBSI, the Contractor
shall give due advance notice (usually not less than three days) and provide
details of date, time and type of tests to be performed.

2.3 Upon completion of such T & C procedure, the Contractor shall complete
and sign a testing and commissioning certificate as Appendix A, to the
effect that agreed T & C procedures have been duly carried out.

2.4 Before carrying out any test, the Contractor shall ensure that the
installations comply with the statutory requirements and regulations.

2.5 Part of the testing & commissioning may be required to be carried out in
Suppliers premises in accordance with the provisions in the
General/Particular Specification.

2.6 The testing & commissioning of systems under various sections may be

BSBTC-01 2
required to be carried out in parts or as a whole depending upon the status
of the progress of work or as dictated by the requirements of the Contract.

2.7 It must be ensured that the personnel carrying out the tests are trained,
experienced commissioning engineers and for specialised items such as
refrigeration plants, control equipment etc., these may be carried out by the
manufacturers own T & C engineers if necessary.

3. Testing and Inspection

3.1 The requirements are in general as specified in the latest General
Specification for Air-conditioning, Refrigeration, Ventilation and Control
Systems issued by Building Services Branch of Architectural Services
Department, herein after described as General Specification. If there is any
discrepancy between this procedure and the General Specification, the
General Specification shall take precedence.

3.2 The Contractor shall carry out the tests and inspections as shown in Part 3
and record the test results on Part 4 of Appendix A and as agreed between
the Project BSE and the Contractor.

3.3 The Contractor shall provide all the necessary staff, labour, materials and
equipment for a thorough test and examination of the installation.

3.4 The purpose of this T & C procedure is to provide the Contractor a
guideline which would ensure that the building environmental systems
produce the design objectives. It includes :

(i) The balance of air and water distribution.

(ii) The adjustment of total system to provide design quantities.

(iii) The electrical measurement.

(iv) The verification of performance of all equipment and automatic
controls.

(v) The sound and vibration measurement.

3.5 The objectives as outlined above can be accomplished by :

(i) Checking installations for conformity to design.

(ii) Measurement and establishment of fluid quantities of the system as
required to meet design specification.

(iii) Recording and reporting the results.

3.6 The procedure covers the following sections of testing & commissioning :

(i) Preliminary checks


BSBTC-01 3
(ii) Setting to work and balancing the systems

(iii) Recording of test data

4. Statutory Inspection/Commissioning

4.1 After the proper testing and commissioning of the Air-conditioning,
Refrigeration, Ventilation and Control Systems, the Contractor shall notify
the appropriate Authority, through the PBSE, on the completion of the
installation and its readiness for inspection and testing.

4.2 Before operating the system to carry out T & C, the following steps should
be followed :

(i) Obtain design drawings and specifications and to be thoroughly
acquainted with the design intent.

(ii) Obtain copies of approved shop drawings of all air handling
equipment, outlets (supply, return and exhaust) and temperature
control diagrams.

(iii) Compare design to installed equipment and field installation.

(iv) Check the system from the air handling equipment to terminal units
to determine variations of installation from design.

(v) Check filters and dampers (for both volume control and fire
protection) for correct and locked position, and temperature control
for completeness of installation before starting fans.

(vi) Obtain manufacturers outlet factors and recommended procedure of
testing. Summation of required outlet volumes permits a crosscheck
with required fan volumes.

(vii) Obtain schematic diagrams of system as-built ductwork and piping
layouts to facilitate reporting.

4.3 During construction certain tests will have been carried out on the
installations to ensure their suitability for operating at the design
conditions. Such test certificates have to be issued together with
certificates of any works tests.

4.3.1 Works Tests

a) Works tests shall be carried out in accordance with the type
normally associated with the specified item of equipment and
to the standards as laid down in the Specification and the
Conditions of Contract.

b) Works static pressure tests will be carried out on such items of
plant and equipment as pressure vessels, water coils, heat
exchangers and plate exchangers, radiators and convector

BSBTC-01 4
elements, and all items of plant or equipment handling
refrigerant, as laid down in the Specification and the
Conditions of Contract.

c) Dynamic rotation tests will be carried out on such items as fan
impellers and drives, compressor, pump impellers and drives.
Tests shall be conducted through the entire rotational speed
range up to a maximum of 150% design operating speed if the
provision have been made in the Conditions of Contract. When
items of plant are purchased ex-stock, manufacturers test
certificate will suffice.

d) Rotational test on electric motors will not be carried out if the
equipment is constructed to the requisite current British
Standard or any other approved standards.

4.3.2 Welds in Piped Services

a) The welds shall be inspected by means of cutting. The total
number of welds to be inspected should be limited to 2.5% of
the total. If any of the welds are found to be of sub-standard,
equal number of further welds shall be cut out.

b) At least two welds per operative shall be inspected. Each
welder employed on the works shall be allocated an
identification number and each site weld shall be stamped with
the appropriate identification number to identify the operative.

c) Where required by the Particular Specification, some welds on
large bore or high pressure mains may be subject to testing by
radiographic or ultrasonic methods. Such non-destructive
testing should be carried out by specialized laboratories who
both perform the tests and analyse the results.

4.3.3 Pressure Testing of Piped Services

a) Pressure testing of piped services systems, or any section of a
completed system, shall be completed prior to the application
of any thermal insulation to the cleaned pipe surfaces.

b) Ensure that all plugs, caps, tees and drain fittings required to
enable the tests to be carried out have been provided.

c) Before hydraulic tests are carried out, all safety valves, gauges
etc. shall be effectively isolated or removed. For all non-
destructive safety equipment, these shall be effectively tested at
their design working pressure during commissioning of the
installation.

d) Tests on lengths of pipe or portions of systems shall be applied
by filling the section to be tested with water and raising its
pressure to the figure quoted in the Specification.

BSBTC-01 5

e) The section shall then be left fully isolated without further
strokes of the pump and all joints must remain watertight for a
period of at least two hours. As to whether or not the section is
sound shall be governed by the rate at which the pressure falls.

f) Any fault discovered during such tests shall be at once
remedied and the test reapplied until the section under test is
considered sound. Remedial work shall conform with all the
requirements of the General and Particular Specification for
materials and standards of workmanship.

g) Upon completion of the test, the water shall be released and
drained away as rapidly as possible, the section being then
thoroughly sluiced through to ensure the removal of as much
dirt and dross as possible before being refilled and put into
service.

4.3.4 Air Leakage Test for Ductwork

a) Where required by the Specification, all air-conditioning supply
ductwork connected to central air handling units shall be tested
for air leakage in accordance with - HVCA (V12) Specification
for Sheet Metal Ductwork (DW series).

b) For preliminary and visual test, the method will include using
chemical white smoke generators. All openings in the
ductwork shall be properly sealed followed by the introduction
of smoke.

4.4 The flow-chart in Appendix C provides the sequence, responsibilities and
guidelines for the testing and commissioning procedure.

4.5 Precommissioning Checks

4.5.1 Water Distribution System

4.5.1.1 System Cleanliness

Irrespective of the precautions taken during the construction
stage to keep the internal surfaces of pipework clean, it should
be assumed that it has not been done so and one of the
following procedures shall be used to clean the system.

4.5.1.1.1 Flushing

a) Divide the pipework system into self-draining sections so that
the maximum possible flushing rate is achieved.

b) Isolate items which are particularly sensitive to dirt, such as
pumps, small bore coils and tubes, including induction and
other room unit coils and spray nozzles. Washers, cooling

BSBTC-01 6
tower basins, feed and other tanks which may have
accumulated with deposits during manufacturing or installation
should also be isolated and flushed independently.

c) Where make-up or feed tanks are used for flushing, ensure that
the maximum possible pressure is sustained on the system
during the flushing process. This may necessitate the provision
of a temporary parallel feed of mains water into the tank where
the ball valve has limited capacity. This procedure assumes
that the connection of the section from the tank is at a high
point in the section being flushed.

d) Ensure :

(i) that flushing is carried out from the upper to the lower
sections of a multi-section system, finishing with the
lowest point; initial flushing should always be from small
bore to large bore pipe. Particular care is required on
reverse return systems and systems with roof-top chiller
or boiler plant;

(ii) that the large bore outlet is not opened until the section
being flushed is fully primed;

(iii) that the maximum possible flow rates are used;

(iv) that flushing continues until the outflow runs clear.

4.5.1.1.2. Cleaning by Forced Circulation

Where facilities exist, final cleaning of systems can be
achieved by circulation of the medium in order to collect dirt at
filters or other selected points in the system. Where circulation
is achieved by the use of a pump, this action shall be deferred
until the pump has been set to work in accordance with para.
4.6.1.4.

4.5.1.1.3 Chemical Cleaning & Corrosion Inhibiting

Chemical cleaning, if required, shall be carried out as specified
by the specialist. Corrosion inhibiting, where specified, should
be carried out after flushing.

4.5.1.2 State of System

Check :

(i) that where special valve packing is required, e.g. grease
in medium or high temperature system, this shall be in
accordance with manufacturers instructions;

(ii) that pressure tests have been completed throughout;

BSBTC-01 7

(iii) that the system has been cleaned in accordance with para.
4.5.1.1;

(iv) that permanent water connections have been made;

(v) that water treatment is available if specified.

4.5.1.3 Check of System before Filling

Check :

(i) that probes, pockets, pressure gauges, siphons, orifice
plates and taps, and air vents are installed;

(ii) that drains and overflows are connected and free from
blockage;

(iii) that connections to heating and cooling coils and all other
heat exchangers are correct in relation to the design water
flow direction;

(iv) that control and non-return valves are installed the right
way round;

(v) that relief valves are installed as specified and are free to
operate;

(vi) that relief valve outlets are piped away to suitable drain
points;

(vii) the expansion devices for alignment and freedom from
obstruction;

(viii) the presence of special pump priming devices where
specified;

(ix) that the strainer mesh is of the correct grade and material;

(x) that the changeover devices for duplex strainers are
operative and that there are means of isolation for single
strainers;

(xi) that washers, tanks, nozzles and filters are clean;

(xii) that tank covers are provided where specified;

(xiii) that drain cocks are closed and other valves are left open
or closed according to the plan for filling (see para.
4.5.1.5 below);

(xiv) that the feed connection is in its correct location;

BSBTC-01 8

(xv) that all pipework and fittings are adequately supported,
guided and/or anchored where applicable.

4.5.1.4 Mechanical Checks

4.5.1.4.1. Pumps

Check :

(i) the external cleanliness of the pumps;

(ii) that the flow direction is correct;

(iii) that all components, bolts, fixings, etc., are secured;

(iv) that the impeller is free to rotate;

(v) the level and plumb of pump and motor shaft and slide
rails; direct drive pumps require particular attention in
this respect;

(vi) the anti-vibration mountings for correct deflection;

(vii) that the correct drive is fitted;

(viii) that the pipework imposes no strain at the pump
connections;

(ix) the securing and alignment of pulleys and couplings;

(x) the belt tension and match;

(xi) the cleanliness of the bearing;

(xii) that the lubricant is fresh and of the correct grade;

(xiii) that the coolant is available at the bearings when
specified;

(xiv) that glands are correctly packed and the gland nuts are
finger-tight only, pending adjustment to correct drip rate
after start-up;

(xv) that drive guards are fitted and the access for speed
measurement is provided.

4.5.1.4.2. Motorized Valves and Float Switches

Check :

(i) that the valves are installed the correct way round;

BSBTC-01 9

(ii) that the valve spindles are free to move;

(iii) for freedom from excessive looseness;

(iv) the fit of pins;

(v) the rigidity of the mountings;

(vi) the stiffness of the linkage members;

(vii) the tightness of locking devices;

(viii) the bearing lubrication.

4.5.1.5 System Filling

Charge the system with water (treated, if so specified) to a
prepared plan, the object of the plan being successful venting
by filling from the bottom upwards forcing the air to high
points - for venting to atmosphere. Careful consideration
should be given to the stage of valves and air vents before and
during filling to avoid air-locks and excessive spillage. Take
care not to exceed the working pressure of the system when
filling from a high pressure source. When the whole system is
filled, disconnect the filling source, open the permanent supply
and adjust the tank levels.

4.5.1.6. Electrical Checks

Prior to the initial running of any electrically driven pump,
valve or electric water heater, the following procedures should
be adopted.

4.5.1.6.1. With all Electrical Supplies Isolated

Check :

(i) the local isolation of motor and control circuits;

(ii) that there are no unshrouded live components within the
panels;

(iii) that the panels and switchgears are clean;

(iv) that the motor and surrounding areas are clean and dry;

(v) that the transit packing has been removed from contactors
and other equipment;

(vi) that there is no mechanical damage to switchgears and
that thermostats are of a suitable range to operate at

BSBTC-01 10
ambient temperature (see para. 4.6.1.2);

(vii) that all mechanical checks on the pump and motor or
valve are completed (see para. 4.5.1.4);

(viii) that all connections are tight on busbars and wirings;

(ix) that the internal links on the starter are correct;

(x) that all power and control wirings have been completed
in detail to the circuit diagram (paying special attention to
circuits for star-delta connected or specially wound
motors);

(xi) that the fuse ratings are correct;

(xii) that the starter overloads are set correctly in relation to
the motor name-plate full load current;

(xiii) that the dashpots are charged with the correct fluid and
the time adjustments and levels are identical;

(xiv) that insulation tests on the motor have been performed
satisfactorily;

(xv) that the adjustable thermal cut-outs are set correctly
(check manufacturers test certificates);

(xvi) that all cover plates are fitted.

4.5.1.6.2 With the Electrical Supply Available

(i) Check that the declared voltage is available on all supply
phases.

(ii) Where motor powers are substantial or reduced voltage
starting or complex interlocks are involved, the control
circuit logic and the starter operation should be tested
before the motor is rotated. The supply should first be
isolated by the withdrawal of the two power fuses not
associated with the control circuit or the disconnection of
cables. The red phase shall be used for control circuit
normally. The control circuit fuse must be checked to
ensure that it is rated to give the correct discriminatory
protection to the control circuit cables. The control
circuit should be activated and the starter operation
observed. Adjust the timers. Check for positive
operation of all contactors, relays and interlocks. Finally,
open the isolators, reinstate the power connections and
close the isolators.

(iii) Where small motors have direct-on-line starting and

BSBTC-01 11
simple control circuits, the starter operation, etc., should
be checked when first starting the motor.

(iv) Never energize electric valve motors until the checks
(para. 4.5.1.4.2), have been completed.

4.5.2 Air Distribution System

4.5.2.1 System Cleanliness

Prior to the fitting of filters and washer elements, ensure that
the environment is clean and then proceed to check the
following for cleanliness :

(i) air intake screens;

(ii) fan and other equipment chambers;

(iii) floor gulley and all drainage traps;

(iv) fan internals;

(v) heater and cooler batteries;

(vi) cooling coil trays;

(vii) washer tanks;

(viii) humidifiers;

(ix) eliminators;

(x) dampers;

(xi) ducting and other airways;

(xii) sensing elements;

(xiii) terminal units;

4.5.2.2 Air Regulating Devices and Other Components Within
Airways

Checks :

(i) that turning vanes, thermal insulation, acoustic linings,
battery fins and sensing elements have been fitted and are
undamaged;

(ii) that heater and cooler batteries, humidifiers, filters,
silencers, fire dampers, sail switches, volume control
dampers etc., are installed correctly in relation to air

BSBTC-01 12
flow;

(iii) the damper free-movement, clearances seating pining to
damper spindles, position of blades with respect to
quadrant indication, relative positions of blades in multi-
leaf dampers;

(iv) the control linkages on motorized dampers for alignment,
rigidity, lubrication and free movement without
slackness;

(v) that dampers throughout the system are secured in open
position with damper actuators disconnected;

(vi) the free movement of fire dampers together with the
location of, access to and fitting of, fusible link assembly;
all fire dampers are finally secured in open position;

(vii) that all adjustable louvres are set without deflection, i.e.
normal to face of grille. Adjustable cones on diffusers
are set either all in the fully up or all in the fully down
position;

(viii) that test holes are provided for measurement of total air
flow.

4.5.2.3 Visual Checks for Air tightness

It is assumed that pressure testing of high velocity system
ductwork is carried out during construction. This is essential
on all high velocity systems and is widely required for low
velocity systems.

Check :

(i) the builders work ducts and shafts seals;

(ii) that access doors to plant equipment are sealed around
the whole periphery;

(iii) the ductwork joints, including flexible couplings;

(iv) that inspection covers are fitted;

(v) that drain water seals are fitted;

(vi) that plugs or covers for test holes are fitted.

4.5.2.4 Mechanical Checks

4.5.2.4.1. Fans


BSBTC-01 13
Check :

(i) the external cleanliness of fans;

(ii) that all components, bolts, fixing, etc., are secured;

(iii) that the impeller is secured, free to rotate, of correct
handing and correct clearances;

(iv) that axial-flow-type fans are installed for correct air flow
direction and, where compounded, in correct order;

(v) the level and plumb of fan and motor shaft and slide rails;

(vi) the anti-vibration mountings for correct deflection;

(vii) the static balance;

(viii) that the correct drive is fitted;

(ix) the securing and alignment of pulleys and couplings;

(x) the belt tension and match;

(xi) the cleanliness of the bearing;

(xii) that the lubricant is fresh and of the correct grade;

(xiii) that the coolant is available at bearings when specified;

(xiv) that drive guards are fitted and the access for speed
measurement is provided;

(xv) for satisfactory operation of inlet guide vanes over full
range of movement;

(xvi) that fan casings to be earthed are correctly and soundly
bonded.

4.5.2.4.2 Automatic Fabric Filters

Check :

(i) the level mounting;

(ii) the alignment, clearances and free movement of spools,
drives and limit switches;

(iii) the lubrication of spool drive motor, gearbox and spool
bearings.

4.5.2.5 Electrical Checks

BSBTC-01 14

Prior to the initial running of any electrical driven fan, electric
air heater or automatically advancing filter, the following
procedures shall be adopted :

4.5.2.5.1. With all Electrical Supplies Isolated

Check :

(i) the local isolation of motor and control circuits;

(ii) that there are no unshrouded live components within the
panels;

(iii) that panels and switchgears are clean;

(iv) that the motor and surrounding areas are clean; air heaters
are clean;

(v) that the transit packing has been removed from contactors
and other equipment;

(vi) that there is no mechanical damage to switchgears or air
heaters;

(vii) that all mechanical checks on fan, motor and automatic
filter are completed (see para. 4.5.2.4);

(viii) that all connections are tight on busbars and wirings;

(ix) that the internal links on the starter are correct;

(x) that all power and control wirings have been completed
in detail to the circuit diagram. (paying special attention
to circuits for star-delta connected, or specially wounded
motors);

(xi) that fuse ratings are correct;

(xii) that starter overloads are set correctly in relation to motor
name-plate full load current.

(xiii) that the dashpots are charged with the correct fluid and
the time adjustments and levels are identical;

(xiv) that insulation tests on motor have been performed
satisfactorily;

(xv) that the adjustable thermal cut-outs are set correctly;

(xvi) that all cover plates are fitted.


BSBTC-01 15
4.5.2.5.2. With Electrical Supply Available

a) Check that the declared voltage is available on all supply
phases;

b) Where motor powers are substantial or reduced voltage
starting or complex interlocks are involved, the control
circuit logic and the starter operation should be tested
before the motor is rotated. The supply should first be
isolated; then by the withdrawal of two power fuses or
the disconnection of cables followed by the reinstatement
of supply to the control circuit alone, the control circuit
shall be activated and starter operation observed. Adjust
the timers. Check for proper operation of all contactors,
relays and interlocks. Finally open the isolators, reinstate
power connections and close the isolators;

c) Where small motors have direct-on-line starting and
simple control circuits, the starter operation, etc., should
be checked when first starting motor.

4.5.2.6 Electrostatic Precipitators

4.5.2.6.1 Before Approaching the Precipitator :

Establish :

(i) what isolators must be opened and fuses withdrawn to
completely disconnect the precipitator plant from the low
voltage supply. Beware of interlocking circuits which are
energized from elsewhere and where cannot be isolated
local to the precipitator;

(ii) the arrangements for preventing access to any high
voltage component until it is at zero potential;

(iii) adequatelabels for instructions / precautions / warnings to
be deployed at the entrance access to the precipitator.

4.5.2.6.2 Low Voltage Electrical System

With all low voltage supplies isolated, check :

(i) the local isolation of all low voltage circuits;

(ii) that switchgears are clean and undamaged;

(iii) that the transit packing has been removed from contactors
and other equipment;

(iv) that all wiring connections are tight;


BSBTC-01 16
(v) that all wirings have been completed in detail to circuit
diagram;

(vi) that all cover plates are fitted.

4.5.2.6.3. High Voltage Electrical System

Only a skilled and experienced person should be allowed to
enter the precipitator casing; he should have with him the
interlock key which controls the opening of the access door to
the section of precipitator which he is entering or a fuse link or
other item to prevent the precipitator being energized; a second
person should be stationed outside the door as an observer and
he will normally also be in control of the operation of the
power pack from this position. Before working on any
precipitator system, any residual High Tension (H.T.) charge
must be removed using an earthing tool with insulated handle.
Where the power pack is remote from the precipitator, a
shorting bar should be securely fixed between earth and each
H.T. feed to the precipitator.

The inbuilt features which prevent access to high voltage
components until at zero potential shall, without fail, be
checked as follows :

(i) no access to precipitator section via inlet or outlet
ductwork connections. Where equipment is being used
as a barrier, beware of items which are demountable
without tools such as pre-filter cells. Such items should
always be supplemented by safety screens as should
dampers with blade width exceeding 100 mm;

(ii) any mechanical interlock correctly links H.T. circuits to
earth before access door can be opened and
simultaneously de-energizes the H.T. primary circuit to
prevent overload caused by the earth link;

(iii) no duplicate keys on site for the mechanical interlock
system;

(iv) any safety switches fitted to access doors break the Low
Tension (L.T.) interlock circuit and destroy H.T. potential
before the door is open wide enough to allow an arm or
leg to reach a H.T. component within the precipitator
casing; also check that switches are held positively open
to prevent manual closure or closure by spring failure
whilst access door is open;

(v) check that H.T. potentials are reduced to a safe level
within the time it takes to open the door and reaches any
H.T. component. This will be of particular importance
when door safety switches do not merely augment a

BSBTC-01 17
mechanical interlock earthing system but are also the sole
safety interlock, the value of bleed resistors connected
across each capacitor holding H.T. charge will be critical;

(vi) a solid copper or aluminium bond connects the H.T.
power pack and filter frame to the building main earthing
system.

4.5.2.6.4 Cleanliness and Mechanical Condition

With all electrical supplies isolated, H.T. circuits earthed and
precautions for staff adopted in accordance with para. 4.5.2.6.3.

Check :

(i) for unsafe ladders, walkways or dangerous projections;

(ii) the internal cleanliness of casing, components, including
insulators and ductwork connections;

(iii) that all components are in place and correctly connected.
No damage or distortion to ionizer and collector sections.
No obvious foreign items in the precipitator cells.
Ionizer wires of the correct diameter and type to be
provided and to be correctly tensioned. Displacement of
these wires from the centres between neutral electrodes
should not exceed 5% of the distance between the neutral
electrodes. No distortion of collector plates and gaps
between plates shall not vary by more than 10%;

(iv) that the wash water and fluid coating systems are
completed, reservoir is charged with correct fluid and
drainage systems are completed and free from blockage.
Connection is provided for manual wash;

(v) that fabric filter sections are loaded with media; if
automatic advancing then checks listed in para. 4.5.2.4.2
shall be carried out.

4.5.2.6.5 Interlock Sequence and Alarm Systems

With electrical supply available check :

(i) that the precipitator interlock sequence is correct;

(ii) that all safety and failure alarm systems are functioned
correctly.

4.6 Setting to Work & Balancing

4.6.1 Water Distribution System


BSBTC-01 18
4.6.1.1 General

a) It is not possible in a document of this nature to embody
every type of plant layout that the commissioning
engineer is likely to encounter in the field. The system as
detailed in Fig. 1 at the Appendix C includes only those
plant items necessary for clarification of the regulation
method described. The procedure given here may have to
be adapted to suit the particular arrangement.

b) The method of manual regulation detailed below is
applicable to the following systems :

(i) Constant volume, variable temperature primary circuits.

(ii) Constant volume, variable temperature secondary
circuits.

(iii) The maximum flow situation in a variable volume system
designed without diversity.

4.6.1.2 Procedures

This section defines the procedures to be carried out in order to
achieve a water distribution system which is working
satisfactorily and regulated appropriately. These works should
normally be carried out with the medium at ambient
temperature and therefore there is no need for heated or chilled
water to be available. It is unwise, in any event, to allow the
commissioning of heating or refrigeration plant (particular if of
low thermal capacity) unless design primary circulation flow
rates have been established and any likelihood of primary flow
rate variations due to modulation of unbalanced secondary
systems have been eliminated.

4.6.1.3 Checks Prior to Pump Start-Up

a) Check that all normally open isolating and regulating
valves are fully open and that all normally close valves
are closed. In the case of thermostatic valves it is
essential that provision for fully opening of the valves is
available. Most electric motorised valves have either
provision for manual override of normal control using a
switch on the main control box or a facility to position
the valves seat mechanically. Pneumatically operated 3-
way valves rarely have this facility. It is, therefore,
necessary to ensure that the control pneumatics are
commissioned to the extent that the controller set point
can be adjusted to its extremes, to position the valve fully
open or fully closed. Space temperature at the sensing
point of the controller in the dynamic mode must be
considered at this point, i.e. reducing the control set point

BSBTC-01 19
of a chilled water valve controller which is already
sensing a low temperature, will not have the desired
effect; provision of a local form of valve heat
pressurisation must then be considered, such as a portable
air compressor.

b) Open all control valves to full flow to heat exchangers of
branch circuits.

c) Fully open the return and close the flow valve on the
pump, close valves on standby pump. Closing the flow
valve on the duty pump will limit the initial starting
current, which is usually excessive at the first time a
pump is running due to bearing stiffness.

4.6.1.4 Initial Running of Electrically Driven Centrifugal Pump
Set

4.6.1.4.1 Initial Start

On activating the motor starter,

Check :

(i) that the direction and speed of rotation of the motor shaft
are correct;

(ii) that the motor, pump and drive are free from vibration
and undue noise;

(iii) the motor starting current for sequence timing
adjustment;

(iv) the motor running current on all phases to ensure that
they are balanced between phases. The flow valve can be
opened at this point to raise the running current to say 50
per cent of the name-plate full load current;

(v) that there is no sparking at the commutator or slip rings;

(vi) that there is no overheating of the motor (see BS 587 and
BS 5000, Part II);

(vii) that there is no seepage of lubricant from the housing;

(viii) that the water flow to water-cooled bearings is sufficient;

(ix) the reduced speed and motor running current on multi-
speed motors.

4.6.1.4.2 Initial Run


BSBTC-01 20
a) A light load should be sustained until the commissioning
engineer is satisfied from the checks listed in para.
4.6.1.4.1 and from motor insulation test readings that
further load may be applied. Repetitive starting of the
motor should be avoided to prevent over-stressing of the
fuses, switchgear and motor.

b) Gradually open the discharge valve until the motor
current reaches either the design value or the motor full
load current, whichever is the lower.

c) Check the pump pressure developed by means of the
pump altitude gauges against the design pressure. If
excessive pressure is developed at this stage, the cause
should be investigated.

d) Adjust the discharge valve so that the flow as determined
roughly from the pump characteristic is between 100 and
110 per cent of the design value. Note that the motor full
load current is not exceeded.

4.6.1.4.3 Running-in Period

a) The pump should be run in accordance with the
manufacturers recommendations and should be under
fairly continuous observation. It should not be left
running outside normal working hours unless attended.
During this time check that the bearings and motor
temperature remain steady, that no noise or vibration
develops and that no bolts or fixing works loose.
Observations may then become less frequent, but it is
advisable while later commissioning other parts of the
system, to check the pump from time to time. During the
first part of the running-in period :

(i) Vent all high points from time to time. When possible
the medium should be heated to maximum permissible
levels to assist in removing air from the heating system.

(ii) Adjust the gland nuts of the pump glands to give the
correct drip rate. (Not applicable to mechanical seals.)

b) After eight hours of running, check all strainers. If these
are clean, regulation can commence. If they are dirty,
clean the strainers, and run again for at least eight hours
and then re-check.

4.6.1.4.4 Standby Pump

On installations with a standby pump, this standby pump
should also be commissioned. This pump can be checked
against the other and in the unlikely event of failure of the first

BSBTC-01 21
pump, commissioning can continue using the second pump.
However, a full diagnosis of the reasons for the failure of the
duty pump must be made before energizing the standby pump
to ensure that any contributory causes are remedied.

4.6.1.4.5 Secondary Pump

In systems with primary and secondary pumps, starting
procedures for the primary pumps should be dealt with first.
Isolate the secondary system during this period to prevent any
accumulated deposits not removed during the flushing process
being carried over into the secondary services. After the final
check of strainers referred to in para. 4.6.1.4.3.b, the secondary
system can be opened up and the starting procedure for the
secondary pumps initiated. Only after a final check of both
primary and secondary strainers should actual regulation
commence.

4.6.1.5 Regulation of Water Flow

4.6.1.5.1 The procedures described in this section are a guide to the
principles of regulation by proportional balance.
Regulation is achieved by measuring the pressure drop
across a device with a constant flow coefficient capacity
index. Balance is obtained by varying the water flow
across the device so that the ratio of actual water flow
rate to the design water flow rate (as calculated from the
square law relationship of water flow rate to pressure
drop) is the same (or within designers tolerance) across
devices. The device may be a venturi-meter, an orifice-
plate, a control valve with a known calibrated flow
characteristic, a calibrated regulation valve or any device
with a constant flow coefficient and a calibrated
characteristic reliable as to accuracy and repeatability.
Where valves are used they are used in the fully open
position, i.e. as a form of fixed orifice. For greater
accuracy of absolute flow measurement, only devices
covered by British Standard BS 1042 (Measurement of
fluid flow in pipes) should be used.

4.6.1.5.2 For the purposes of illustration of the procedures, the
system as shown in Fig. 1 of Appendix C will be used.
Although the procedures are equally applicable to heating
and condensing water circuitry, a chilled water system
will be used to illustrate the method. In the heat
exchange processes in chilled water systems, temperature
differences between the two fluids are generally very
small by comparison with heating systems and for this
reason the performance of terminal plant is considerably
more sensitive to any deviations from the design water
flow rate. Hence, the T & C procedure requires more
exacting tolerances when balancing this type of system.

BSBTC-01 22
A series of branch circuits each with several loads have
been indicated, flow to each load being controlled by a
three-way control valve. Three-way valves in both
mixing and diverting applications plus a wild non-
controlled coil have been included in the diagram to
demonstrate the flexibility of the regulation procedures.
In the system illustrated at Fig. 1 of Appendix C, the flow
line to each terminal unit is fitted with a
regulating/isolating valve which has in-built pressure
tappings. This valve is used in its fully open position as a
fixed orifice device for water flow rate measurement.
The flow measurement may be made anywhere in the
branch circuit. A fixed orifice is sometimes incorporated
into the regulating valve in the return line. The principle
of the balancing method remains the same. The return
line from each terminal unit is fitted with a double
regulating/isolating valve which is regulated and locked
in position during the balancing procedure. Where there-
way valve is fitted, a double regulating/isolating valve is
installed in the bypass, e.g. across the heat exchanger to
balance the bypass with the coil.

4.6.1.5.3 Initial Check of System Water Flow Rates

a) Check the pressure drop across the associated flow
regulating valve of each terminal unit by connecting a
manometer between points a and b. (Refer to terminal
unit A1 in Fig. 1 of Appendix C) It should be
remembered that the reading obtained is related to the
design water flow rate by a square law, not a linear
relationship. This can be represented by the following
expression :

P
1
Q
1
2

P
2

=
Q
2
2

. .. .. .. . W.1

Where :

P1 = Actual pressure drop .. .. kPa

P2 = Design pressure drop .. .. kPa

Q1 = Actual water flow rate.. .. m
3
/s

Q2 = Design water flow rate.. .. m
3
/s

Hence the actual percentage of design water flow rate obtained
can be deduced from the following calculation :

Actual percentage of design water flow rate obtained



BSBTC-01 23
P
1


=
P
2

x 100.. .. .. .. ..W.2

b) Inspection of the percentages of obtained water flow rate
to design water flow rate will indicate which is the least
favoured (index) branch and which is the most favoured
branch.

c) At this stage manually set the three-way valve to the
bypass position and regulate the bypass valve S so that
the pressure drop between a and b equals the reading
previously obtained with the three-way valve in the full
flow position. Lock the bypass double regulating valve.
This procedure is not part of the balancing of the main
water distribution system but is the local commissioning
of the water flow control of the three-way valve.

4.6.1.5.4 Balancing of Terminals

Start to balance the most favoured branch. The water flow rate
of each terminal unit should be balanced to the water flow rate
of the index terminal unit in that branch. Each branch is dealt
with independently. (The main branch valves A, A, B, B, C,
C in Fig. 1 of Appendix C are all fully open at this stage).
Assume branch A-A has the highest unit A1 (remote in
hydraulic terms relative to the circulating pump) is the least
favoured. If it is not, connect one manometer across valve No.
1 and a second manometer across the regulating valve
associated with the least favoured terminal unit. Regulate the
down-steam double regulating valve No. 2 until the percentage
of design water flow rate across the two valves are equal (or
within the designers tolerances). Leaving the first manometer
connected across valve No. 1 (a and b) while the rest of the
branch A-A is balanced. Connect the second manometer
across valve No. 3. Regulate valve No. 4 until the percentage
of design water flow rate is the same (or within the designers
tolerances) as valve No. 1. Repeat this procedure for all valves
on branch A-A. Remove both manometers and start on the
next most favoured branch. Carry on until the water flow rates
of all terminal units on all branches are balanced within each
branch.

4.6.1.5.5 Balancing of Complete Branches

For this stage, the branch regulation valves (A, B and C) will
be the measuring stations. Check the percentage of design
water flow rate across each branch regulating valve. It will
then be apparent that which is the index branch (say A-A). Set
the first manometer across valve No. A and the second
manometer across valve B until the percentage of design water
flow rates across the valves A and B are equal (or within the
designers tolerances for branch balance). Leaving the first

BSBTC-01 24
manometer connected across valve A, repeat this procedure for
all branches (in this example for branch C-C) working back
from the most remote branch to the branch nearest the pump.
(Where, at the start of branch balancing, if the most remote
branch is not the index or least favoured branch, it should be
made so, in the manner described for terminal balance.)

4.6.1.5.6 Secondary Mixing Set Regulating

For the purpose of illustration it is assumed that the design
water flow rate as delivered by the secondary circulating pump
is in excess of the design water flow rate of the secondary
mixing three-way valve. The first manometer is connected
across valve No. 11 and the second manometer across valve
No. 14. With valve No. 13 fully open and the secondary three-
way valve in the full flow position, the percentage of design
water flow rate through valve No. 11 should be in excess of the
percentage through valve No. 14. (Regulate valve No. 13 until
the percentage of design water flow rate are equal (or within
the designers tolerances). Manually set the secondary three-
way valve to the bypass position and regulate valve No. 12
until the percentage of water flow rate through valve No. 11
equals the percentage obtained with the three-way valve in the
full flow position.

4.6.1.5.7 Secondary and Primary Final Regulation

Total water flow is measured by connecting a manometer (or
other accurate measuring device) across the total flow
measuring device such as an orifice plate or venturi meter. The
secondary total water flow rate is regulated first by adjustment
of valve No. 15 until the pressure drop across the total flow
device equals the design pressure drop. This procedure is
repeated finally on the primary circuit with the manometer
connected across the primary total flow measuring device and
adjusting the double regulating valve No. 16. At this stage re-
scan all the measuring stations for record purposes including
the pump differential pressures and the evaporator pressure
drop and, where possible, check against the manufacturers
data.

4.6.1.5.8. Other Regulating Valves

Valves incorporating an integral orifice plate, double regulating
facility and metering station as a single unit, or double
regulating valve plus separate orifice plate and metering station
are also available, this eliminate the need for a regulating valve
with in-built pressure tappings. The T & C procedures would
be similar but check with the manufacturer.

4.6.2 Air Distribution System


BSBTC-01 25
4.6.2.1 Precautions Against Airborne Dirt

The system should have been cleaned internally in accordance
with para. 4.5.2.1 but further precautions shall be taken before
starting the fans for the first time :

(i) disconnect final flexible connections to terminal units
such as induction units and blender boxes which are
susceptible to faulty operation through dirtiness;

(ii) preferably remove all high efficiency terminal filters
which are susceptible to rapid choking;

(iii) check that suitable temporary protection has been
provided for anything within spaces served by the system
which could be damaged by initial discharge of dust from
supply outlets at first start-up;

(iv) install main inlet filter cells, properly coated as necessary,
to avoid introducing additional dirt into the ductwork
system after start-up. Check seating of cells for
airtightness. Commission automatic fabric and
electrostatic filters in accordance with para. 4.6.2.2 and
4.6.2.3;

4.6.2.2 Automatic Fabric Filters

a) Preliminary checks in accordance with para. 4.5.2.4.b and
4.5.2.5 shall have been completed.

b) Install filter media in accordance with manufacturers
instructions.

c) Energize the filter without air flow. With the differential
pressure control device looped out, close the isolator
controlling supply to filter and test operation by the
manual advance switch. Leave the filter on manual
advance until the correct total air flow is established
through the filter.

d) The correct total air flow through the filter shall be
established as part of the procedure for regulation of air
flow (see para. 4.6.2.5 below).

e) Commission the differential pressure controller after
establishment of correct air flow as described in para.
4.6.2.5.7 for which the clean filter condition will
normally have been manually selected. An inclined
manometer with pressure sampling points adjacent to the
filter fabric will be used to measure the prevailing static
pressure drop across the clean filter and this will be
recorded. The filter may then be progressively blanked

BSBTC-01 26
off (e.g. with cardboard) until the manometer indicates
the design dirty filter pressure drop. The differential
pressure control will be adjusted to start advancing the
filter at this dirty filter pressure drop and to stop
advancing the filter at the design clean filter pressure
drop.

4.6.2.3 Electrostatic Precipitators

Only a skilled and experienced person should be allowed to
enter the precipitator casing; he should have with him the
mechanical interlock key which controls the opening of the
access door to the section of precipitator which he is entering or
a fuse link or other item to prevent the precipitator being
energized; a second person should be stationed outside the door
as an observer and he will normally also be in control of the
operation of the power pack from this position. Before
working on any precipitator system, any residual H.T. charge
must be removed using an earthing tool with insulated handle.
Where the power pack is remote from the precipitator a
shorting bar should be securely fixed between earth and each
H.T. feed to the precipitator.

4.6.2.3.1 Preliminary Checks

Under no circumstance shall commissioning proceed until all
checks listed in para. 4.5.2.6 have been completed.

4.6.2.3.2 Water Wash and Fluid Coating Systems

a) Commission the wash and coating systems in accordance
with para. 4.5.1 and 4.6.1 Adjust sequence timers.

b) The precipitator should be washed prior to initial
energizing and if specified coated with fluid, allowing
correct drainage periods to elapse. (Note : This may be a
matter of hours.)

4.6.2.3.3 Automatic Fabric Filter Sections

Commission any automatic fabric filter sections in accordance
with para. 4.5.2.4.2, 4.5.2.5 and 4.6.2.2.

4.6.2.3.4 Initial Energizing of Precipitator Without Air Flow

(i) Check that no one is inside precipitator casing, that
access doors are closed and that no entry can otherwise
be made to the precipitator interior.

(ii) Cancel and lock out any remote control system for
precipitator.


BSBTC-01 27
(iii) Switch on precipitator.

(iv) Check that there is no flash-over problem and that
indications from meters and lamps on precipitator control
panel are normal. Faulty operation at this stage will
probably indicate that a preliminary check has been
missed or that water is still present from the initial wash.
All safety measures listed in para. 4.5.2.6.3 must be
implemented before entry to the precipitator casing.

(v) Restore full automatic control sequence ready for the
establishment of air flow through the precipitator.

4.6.2.3.5 Application of Air Flow to Precipitator

When air flow is established through the precipitator (see.
4.6.2.4.5) :

a) check that there is no excessive flash-over (say, an
average of over five per minute per square metre of the
face area). This may be caused, for example, by the lack
of correct pre-filtration, no lint screen etc., in main or
recirculation ducts, presence of water, incorrect air
velocity or excessive H.T. voltage;

b) an inspection should be made of the de-energized
precipitator after a few hours operation with air flow
established (see para, 4.6.2.4.5). Absence of dirt staining
on any ionizer neutrals, etc., may indicate H.T.
disconnection;

c) the H.T. voltage shall be checked at ionizer and collector
sections. Unless otherwise specified the H.T. voltage
should be within +3% of the nominal figure specified at
the mean declared L.T. voltage. Polarity should normally
place positive voltage on the ionizer section to limit
ozone generation. Measurement of H.T. voltage shall be
by means of an instrument comprising high stability
resistance chain with high sensitivity milliammeter in
series, or electrostatic voltmeter across one section of the
chain. Only a skilled and experienced operator should
attempt measurement of H.T. voltage. Great care is
necessary to avoid contact with live parts of the meter
and no part of the meter or its connections should be
touched when it is connected to H.T. components; any
such connections should normally be in special H.T.
cable to avoid current leakage. Readings should normally
be made with the meter placed within the precipitator
casing and observed from the outside through the
observation window;

d) the correct total air flow through the precipitator shall be

BSBTC-01 28
established as part of the procedure for regulation of total
air flow (see para. 4.6.2.5.7);

e) the uniformity of air velocity distribution across the face
of the de-energized precipitator bank should be checked
using an anemometer, after the regulation of total air flow
(see para. 4.6.2.5.7);

To do this, it will be necessary to override the interlock
with the supply fan. It is important to ensure that the
precipitator is cleaned and washed before operating the
fan with the precipitator de-energized;

f) single point measurements of indicated velocity should
be made at the centre of each 300 mm square of the face
area, and where appropriate instrument correction factors
shall be applied to each of the readings. The mean
indicated velocity is then calculated and each of the point
readings is expressed as a percentage of this mean. The
percentage variations of velocity must be within the
tolerances specified. Upper limits will always be critical
and lower limits also in the case of agglomerator/storage
type units. Any failure to meet the specified tolerances
must be rectified.

4.6.2.4 Initial Running of Electrically Driven Fan Set

4.6.2.4.1 Limit the Load

Wherever possible the first start of any motor should be on
light load. With centrifugal fan sets this will normally be
achieved by limiting the mass flow by operation of the main
damper; a knowledge of the fan characteristic is required so
that excessive suction or delivery pressures are not applied to
the ductwork system.

4.6.2.4.2 Initial Start

On activating the motor starter, check :

(i) that the direction and speed of rotation of motor shaft are
correct;

(ii) that the motor, drive and fan are free from vibration or
undue noise;

(iii) the motor starting current for sequence timing
adjustment;

(iv) the motor running current on all phases;

(v) that there is no sparking at commutator or slip rings;

BSBTC-01 29

(vi) that there is no overheating of motor (see BS 587 and BS
170);

(vii) that there is no seepage of lubricant from the housing;

(viii) that there is no overheating of the bearings;

(ix) that oil rings are running freely;

(x) the reduced speed rev/s and the motor running current on
multi-speed motors;

(xi) the rev/s of fan and motor;

(xii) the performance of fan belts in case of abnormal
vibration.

4.6.2.4.3 Initial Run

A light load run shall be sustained until the commissioning
engineer is satisfied from the checks listed in para. 4.6.2.4.2
above and from motor insulation test readings that further load
may be applied. Repetitive starting of the motor should be
avoided to prevent over-stressing of fuses, switchgear and
motor.

4.6.2.4.4 Start at Normal Load

Subsequent to the satisfactory conclusion of the initial light
load run, the machine shall be stopped and restarted at normal
starting load, and the checks listed in para. 4.6.2.4.2 repeated.
Again avoid repetitive starting.

4.6.2.4.5 Running-in Period

After a short run at normal load (a few minutes run will
normally suffice) flexible connections to terminal units, etc.,
and terminal filters (which were removed in para. 4.6.2.1) shall
be restored to position. Subsequently a running-in period shall
be sustained until the fan set is in a reliable continuous running
condition that can safely be placed under the normal operation
and maintenance regime. The regulation of the air distribution
system shall be delayed until the running-in period (which may
last some days) is completed satisfactorily. During the
running-in period the following work shall be conducted;

a) the dynamic balance of the fan and motor shall be
investigated and correct if necessary;

b) the performance of electrostatic precipitators shall be
checked (see para. 4.6.2.3).

BSBTC-01 30


4.6.2.5 Regulation of Air Flow

Regulation of air flow shall be carried out in accordance with
the following procedure. It is applicable to all air distribution
systems which require manual regulation, including induction
unit systems. Only the method of measurement of air flow at
the terminals is particular to the type of system involved.

4.6.2.5.1 Principles

The method consists essentially of working back to the fan
from the remote branches by setting the correct proportional air
flow at each junction of the system in turn (without regard for
absolute values of air flow) and so balancing the system. This
done, the absolute valves of air flow throughout the system are
then brought to their design values simply by adjusting the
main damper only (next to the fan) until the design total air
flow rate is established at the fan.

This theme is illustrated by consideration of air flow at the
junction PQR in a system AZ as shown in Fig. 2 Appendix C.
Q is a dampered branch on the duct RP and the required design
volumetric air flow rates are shown. With damper Q fully open
we may find by measurement that P handles 1.7 m
3
/s, Q
handles 1.3 m
3
/s; 50% and 75% of their design air flow rates
respectively. To balance this junction we would close damper
Q until P and Q handle the same proportion of their respective
design air flow rates : this may result in a balance of P handling
2.0 m
3
/s (60% of its design) and Q handling 1.0 m
3
/s (60% of
its design). It follows that B will now be handling 60% of its
design rate also, i.e. 3.0 m
3
/s.

Now that damper Q is set, provided that we do not alter any
dampers in the system QB downstream of Q or in the system
PA downstream of P, we know that whatever the absolute
value of air flow at R, this air flow will be divided into the
correct design proportions between P and Q at this junction
PQR, i.e. two-thirds to P and one-third to Q.

As we work back up the system towards the fan, adjusting
dampers at other junctions between R and the fan, we will be
changing the absolute values of flows in R, P and Q but not the
ratios of those flows which remain 3:2:1. Ultimately, when all
the junctions have been balanced, we will adjust the main
damper to obtain the design absolute air flow rate in the main
duct from the fan. The correct total air flow will not be divided
by the system as set in the correct proportions at each
succeeding junction, until R is reached where 5.0 m
3
/s will be
flowing; this will now divided into 3.3 m
3
/s in P and 1.7 m
3
/s
in Q exactly as required by the design.

BSBTC-01 31

One final point to note is that in practice, when balancing
successive junctions, a particular routine is adopted both to
avoid accumulative errors and to avoid the need for test points
and dampers in ducts between junctions. Referring to Fig. 3 of
Appendix C, when A, B have been balanced, A, B and C are all
handling the same proportion of their respective design air flow
rates. Thus when we come to balance the junction CDE, D can
be balanced against A or B and not only against C. In practice
A is usually selected as the reference point and the air flows in
B, D and F are in turn balanced against the air flow in A.

Adjusting the distribution dampers to obtain a proportional
balance only, has the important implication that a knowledge is
not required at this stage of the absolute values of air flow rate
in any part of the system. Hence, the instrument used for
measuring the air flow at the terminals or branches of a
distribution system needs not necessarily indicate the true value
of air velocity or pressure. Therefore, inherent errors in the
instrument causing a consistently higher or lower velocity
reading than the true value can be ignored; also provided that
the same method of measurement is used, factors such as those
for effective grille areas are usually self-cancelling and can be
disregarded.

Not until the entire distribution system has been proportionally
balanced will it be necessary to establish the absolute value of
the system total air flow rate.

4.6.2.5.2 State of the System and Building

Before starting the regulation of air flow, it is essential that the
following conditions are fulfilled :

(i) the building is completed and windows and doors are
opened or shut consistent with their normal state; (refer to
para. 4.6.2.5.2.v);

(ii) the duct system is complete and leak-free and in the case
of high velocity systems pressure testing is satisfactory;

(iii) the requirements of checks listed in para. 4.5.2 have been
met;

(iv) normally all main and branch heaters and coolers on
supply systems shall be shut off but on all fresh air
systems, some heating or cooling may be applied to the
main duct only (which handles the total air flow) in order
to temper the air delivered to the spaces. Heat gains and
losses to the ductwork can be minimized by restricting
the difference between duct air temperatures and ambient
temperatures;

BSBTC-01 32

(v) any associated air supply or extract systems which have
not been regulated should normally be shut down. For
balanced systems it may be necessary to balance supply
and exhaust individually against atmosphere (i.e. with
doors open), then operates them together for regulation of
total system air flow.


4.6.2.5.3 Preliminaries to Regulation

To illustrate the regulation procedure a diagram (Fig. 4 in
Appendix C) of a typical low velocity supply air system is
provided. Note, however, that the procedure for other types of
system, including extract systems, is identical to that described
here :

a) Check that the dampers on all terminal grilles or diffusers
1, 2, 3, 4 etc., are fully open; also that sub-branch
dampers AA, AB, etc., branch dampers A, B, C and main
damper M are fully open. All adjustable louvres should
be set without deflection, i.e. normal to face of grille. All
adjustable cones on diffusers should be set either all in
the fully up or all in the fully down position. Set
automatic plant mixing dampers FA and RC to one
extreme position, i.e. normally either full fresh air or full
recirculation.

b) Measure fan motor amps. Throttle main damper M if
necessary.

c) Measure the indicated air flow rates at all terminal grilles
or diffusers 1, 2, 3, 4, etc., preferably using one
instrument. Express these initial measurements as
Indicated percentages of design air flow. It is important
that the design air flow rates (with which the measured
air flow rates are compared) are all based on a common
datum of density, usually that of Standard Air or
occasionally that of air at design density at fan inlet;
during these initial measurements air must be of constant
temperature throughout the distribution system (see para.
4.6.2.5.2.iv) although this temperature datum need not
necessarily equate with the density datum adopted for the
design values of air flow. Note also that variations in
wind, stack effect, fan motor voltage, filter resistance,
etc., will all have some effect on the performance of the
system; for this reason these initial measurements (and
also the final measurements, see para. 4.6.2.5.3.d) will be
made in one quick, continuous operation so that the
readings will normally be truly comparable.

d) Study the general pattern indicated by the initial readings.

BSBTC-01 33
The principal points of interest are :

(i) If the indications are that the total air flow rate handled
by the system is less than 100% of the design then
physical changes to the air handling system will probably
be necessary before regulation can begin. The fan
performance curve and a measurement of fan motor
current will assist in assessment of the total air flow.

(ii) Are there any obvious faults such as design errors,
blockages or leakages indicated, for example, by large
differences of air flow readings between apparently
similar branches and terminals? Such faults will required
correction.

(iii) What are the indicated values of air flow in each branch
A, B, C and each sub-branch AA, AB, etc., of the
system? (obtainable by totalling appropriate sub-branch
values). This will usually determine the order in which
branches and groups of terminals are tackled in the
regulation procedure.

(iv) What is the location of the least favoured terminal (i.e.
the terminal with the lowest percentage of design air
flow) on which sub-branch AA, AB, etc., of the system?
This information is necessary for the regulation of
terminals.

4.6.2.5.4 Regulation Procedure

a) On any one branch, A, B, or C of the system, the first task
is to regulate the terminal dampers on that branch. The
order in which this work is tackled will normally be
decided from the initial readings described in para.
4.6.2.5.3. The branch A, B or C which has the highest
indicated percentage of design air flow will be identified
as, say, C and normally tackled first; on that chosen
branch C, the Sub-branch with the highest indicated
percentage of design air flow will be identified as, say CE
and the group of terminals No. 101 to No. 107 on that
sub-branch CE will normally be regulated first. Next the
group of terminals on the sub-branch with the second
highest indicated percentage of design air flow, say, CD,
will normally be regulated and so on working towards the
sub-branch of the branch C which had the lowest
indicated percentage of design air flow during the initial
readings. By working in this order measurements of air
flow at terminals will be made usually at values which
are as near as possible to the design values of air flow.
Also, this order of work will give the earliest possible
indication that any branch with low initial flow is not
going to reach ultimately the design performance

BSBTC-01 34
required; thus, if necessary, the designer can define
physical changes to the system or revise tolerances on air
flow without delay.

b) For the regulation of terminal dampers, the group of
terminals on each sub-branch of the system will be
treated independently of groups of terminals on their sub-
branches. Thus on sub-branch CE, dampers on terminals
No.101 to No.107 will be adjusted to obtain the same
indicated percentage of design air flow at each of the
terminals within this group No.101 to No.107. (This
percentage could be, say, 130%.) On sub-branch CD the
dampers on terminals No.94 to No.100 will be adjusted
to obtain the same indicated percentage of design air flow
at each of the terminals within this group No.94 to
No.100. (But this percentage could be, say, 110%).
During the regulation of groups of terminals, all the sub-
branch dampers (and the branch dampers) will be left
untouched in the original fully open position.

c) When all the groups of terminals on this chosen branch C
have been adjusted in this way, the next task is to regulate
the groups of sub-branch dampers CA to CE on this one
branch C only. The sub-branch dampers CA to CE will
be adjusted to obtain the same indicated percentage of
design air flow at each sub-branch within this group CA
to CE. Now for the first time each terminal on branch C
will be handling the same percentage of design air flow
as every other terminal, in whatever group, on branch C.

d) When the regulation of both terminals and sub-branch
dampers on branch C has been completed, the branch
with the second highest indicated percentage of design air
flow will be identified from the initial readings as, say, B
and the procedure described in para. 4.6.2.5.4.a and
4.6.2.5.4.b repeated for this branch and so on for any
other branches leaving the branch with the lowest initial
indicated percentage of design air flow (in our case
branch A) to the last. Note that through out this
procedure branch dampers A, B and C are all left
untouched in the fully open position.

e) When the regulation of terminal and sub-branch dampers
has been completed on all branches, the next task is to
regulate the branch dampers A, B and C to obtain the
same indicated percentage of design air flow in each
branch (this could be, say, 115%). Now for the first time
each terminal on the entire system will be handling the
same percentage of design air flow as every other
terminal in the entire system, i.e. 115% throughout.

f) Finally, when the regulation of all branch dampers has

BSBTC-01 35
been completed, the main damper M will be adjusted to
obtain the desired absolute air flow in the main duct.

Each stage of the regulation procedure outlined above is
described in detail in the following para. 4.6.2.5.5 to
4.6.2.5.8.

Note that the order of working suggested is usually the
best one but if necessary a different order can be adopted
provided that a basic rule is not broken : at any junction
in the system (e.g. the junction of terminal with sub-
branch or sub-branch with branch, etc.) no damper, which
regulates the air flow to one arm of that junction, shall be
adjusted until all dampers on either arm downstream of
that junction (in the case of a supply system, but
upstream of that junction in the case of an extract system)
have been adjusted. For example branch damper C shall
not be adjusted until branch dampers A and B and sub-
branch dampers CA, CB, CC, CD and CE have all been
adjusted; and again sub-branch damper CE shall not be
adjusted until terminal dampers No.101 to No.107, sub-
branch dampers CA, CB, CC and CD have all been
adjusted; and again termin.al damper No.107 shall not be
adjusted until terminal dampers No.101 to No.106
inclusive have all been adjusted, etc

Note also that the procedure is normally broken down
into a series of self-contained operations e.g. one group
of terminals is balanced without relation to conditions
elsewhere in a large system perhaps on another day.
Thus the errors in regulation work due to the effect, over
a prolonged period, on system performance of variations
in filter resistance, wind effect, stack effect, etc., are
minimized. Furthermore, errors due to shorter term
variations, for example an instantaneous change in fan
motor voltage, are minimized by regulating the air flow at
each branch or terminal to balance proportionally with
the current air flow at the reference terminal.

4.6.2.5.5 Regulation of Terminal Grilles, Diffusers and Units

Assume it has been decided, in the way described in para.
4.6.2.5.4, to start regulation of terminals at the group No.101 to
No.107 on sub-branch CE. The least favoured terminal on this
sub-branch has been located (see para. 4.6.2.5.3.d). If this
terminal is No.101, the end grille, diffuser or unit, then proceed
as follows :

(i) Measure the indicated air flow at No.101 terminal which
will be used as the reference terminal for this group.
Express this measurement as indicated percentage of
design air flow rate. This percentage will be used as the

BSBTC-01 36
lower balancing limit for this group of terminals.

(ii) With the same instrument and using the same method,
measure the air flow at terminal No.102 and express this
also as indicated percentage of design air flow.

(iii) Compare the indicated percentages of design air flow at
No.101 and No.102.

(iv) If the indicated percentages of design air flow at the two
terminals are within the tolerances specified, the dampers
on these two terminals will require no adjustment.

(v) If the indicated percentages of design air flow is outside
the tolerances specified, close the damper on terminal
No.102 by a judicious amount.

(vi) Measure the indicated air flow now at No.102 and
express this as an indicated percentage of design air flow.

(vii) Return to No.101 and measure the indicated air flow now
at No.101. Again express this as an indicated percentage
of design air flow.

(viii) Compare the indicated percentages of design air flow
now handled by No.101 and No.102.

(ix) If the indicated percentages of design air flow at the two
terminals are now within the tolerances specified, the
terminals are now in balance and the dampers on these
two terminals will hence-forward require no further
adjustment.

(x) If the indicated percentages of design air flow are still not
within the tolerances specified, make a further careful
adjustment of No.102 damper, take new readings of
indicated air flow at No.102 and No.101 and make a
further comparison.

(xi) With practice an operator will normally achieve a balance
by one adjustment of No.102 damper. The rule is to
close No.102 damper by the least amount necessary to
bring the indicated percentage of design air flow at
No.102 below the upper balancing limit when compared
with the reference terminal No.101. By avoiding over-
dampering at terminals the rise in air flow at No.101 is
kept small, making it easy to judge the value to which
other terminals should be regulated.

(xii) When No.102 has been regulated to balance with No.101
(the reference terminal), balance No.103 terminal against
the reference No.101 in the same way.

BSBTC-01 37

(xiii) The terminals No.104, No.105, No.106 and No.107
should be regulated, in turn, to balance with No.101 until
every terminal on that sub-branch CE has been regulated
to balance with No.101; all terminals within this group
are now in balance with each other within the tolerances
specified and need no further adjustment.

(xiv) Note that a change in position of damper No.103 has less
effect on the air flow at No.101 (and No.102) than a
change in position of damper No.102 would have on the
air flow handled by No.101. Therefore, as we proceed
further away from No.101, the reference terminal,
towards the fan during the course of the regulation
procedure, the effect which the closing of a terminal
damper has on the air flow at the reference terminal (and
all other terminals already regulated) progressively
diminishes and it quickly becomes unnecessary to
measure the air flow at the reference terminal in every
case after a terminal is regulated.

(xv) Where the least favoured terminal on the branch is not
No.101, but some intermediate terminal, close No.101
damper until it is the least favoured (checking No.101
against the intermediate terminal which was the least
favoured), then regulate as described in para. 4.6.2.5.5.i
to 4.6.2.5.5.xiv, using No.101 as the reference terminal.

(xvi) Regulate the terminals on each of the other sub-branches
on this branch C using the above procedure. Note that
the terminals on any one sub-branch will be treated as an
independent group and will be regulated to balance with a
reference terminal within the group, e.g. on sub-branch
CD, terminals No.95 to No.100 will be regulated to
balance with reference terminal No.94. Throughout this
procedure the sub-branch and the branch dampers will all
left untouched in the fully open position.

(xvii) The group of terminals on each sub-branch is not in a
state of proportional balance within the required
tolerances. The next step is to regulate the sub-branch
dampers in order to bring all the sub-branches on branch
C into balance with each other within the required
tolerances.

4.6.2.5.6 Regulation of Sub-branches and Branches

The method used is similar to that for the regulation of
terminals (see para. 4.6.2.5.5).

a) Measures the indicated air flow handled by each of the
dampered sub-branches CA to CE and express this as an

BSBTC-01 38
indicated percentage of design air flow. Wherever
possible establish this percentage by measuring the
indicated air flow from one typical terminal on each sub-
branch. The typical terminal selected shall preferably
exhibit a uniform and stable air flow pattern. Only where
the type of terminals on some sub-branches differs from
the type of terminal on other sub-branches will
measurement of duct air flow have to be made on a
sample of the sub-branches which have different type of
terminal, so that indicated air flow rates at the differing
typical terminals may then be compared.

b) Regulate the sub-branches CA to CE by applying the
same procedures described in para. 4.6.2.5.5, i.e. by
considering each sub-branch as a terminal grille on the
branch duct C, but using closer balancing tolerances. The
sub-branch CA will be used as the reference sub-branch
for this operation in exactly the same way that terminal
No.101 was used as the reference terminal for the
regulation of terminal No.101 to No.107.

Note that throughout this procedure the branch damper C
is left untouched in the fully open position. At the
conclusion of the work, the sub-branch dampers will have
been adjusted to achieve the same indicated percentage of
design air flow (within the tolerances specified) in each
of the sub-branches CA to CE.

c) When the regulation of both terminal and sub-branch
dampers on branch C has been completed, the next
branch, in our case branch B, chosen in the way described
in para. 4.6.2.5.4 will be tackled. Once again the first
task here is to regulate the groups of terminals on this
branch as described in para. 4.6.2.5.5, subsequently to
regulate the sub-branch dampers as described in para.
4.6.2.5.6.a and 4.6.2.5.6.b. This procedure will be
repeated for all branches in turn, leaving the least
favoured branch (in our case branch A) to the last.
During this work branch dampers, A, B and C are left
untouched in the fully open position.

d) When the regulation of both terminals and sub-branch
dampers has been completed on all branches, the branch
dampers A, B and C will be regulated to achieve the same
percentage of design air flow at each branch. The method
used will be that described for the regulation of sub-
branches in para. 4.6.2.5.6.a and 4.6.2.5.6.b, i.e. each
branch of the system will be though of as a terminal grille
on the main duct and the procedure described in para.
4.6.2.5.5 adopted. Once again, wherever possible,
establish the indicated percentage of design air flow at
each branch by measuring the indicated air flow from a

BSBTC-01 39
typical terminal on that branch. The branch A will be
used as the reference branch for the regulation procedure
in exactly the same way that terminal No.101 was used as
the reference terminal for the regulation of terminal
No.101 to No.107. During this work the main damper M
will be left untouched in its original position. All
terminals, on whatever branches or sub-branches, are
now in a state of proportional balance within the
tolerances specified and it only remains now is to
regulate the main damper M to achieve the correct
absolute air flow rates to all parts of the system.

4.6.2.5.7 Regulation of Total Air Flow Rate

a) Measure the absolute value of the total air flow rate with
pitot tube and manometer, preferably in the main duct.
Where a reliable reading cannot be obtained in the main
duct, the total air flow can be established by adding the
branch (or zone) air flow rates which in this instance
shall be measured by pitot tube and manometer.

b) Compare the measured total air flow with the design
value. If necessary adjust main duct damper M until the
measured value is within the tolerances specified on the
design value of total air flow. Record in full the results
of the final measurement. Also measure and record the
supply voltage to the fan motor, the motor current and the
fan revolutions per second at the time of this final
measurement of air flow.

Note that with systems which contain fabric filters, or
more particularly absolute filters, the dirtiness of the filter
may have a significant effect on the total air flow rate.
Since the clean filter condition is the only state which can
be readily identified and selected on site, measurements
of total air flow should be made with filters clean
wherever possible and the results obtained should be
compared with the design values at this clean filter
condition. The static pressure drop across the clean filter
shall be measured at the time of the final measurement of
total air flow rate and recorded. Differential pressure
controls for automatic fabric filters shall now be
commissioned in the way described in para. 4.6.2.2.e

c) Where the plant contains auto-dampers for variable
proportions of fresh/exhaust/recirculation or face and by-
pass air proportions, the total air flow measurement and
the main damper regulation shall be conducted with the
auto-dampers at one extreme of the auto-cycle. It may be
necessary to adjust the auto-dampers to obtain the correct
proportions of fresh/exhaust/recirculation or face and by-
pass air when regulating the total air flow. The

BSBTC-01 40
proportions and the total air flow handled at the other
extreme of the auto-damper cycle must then be
investigated and if necessary adjustments will have to be
made to the proportions at this end of the cycle, whilst
maintaining constant total air flow. The characteristics of
the auto-dampers will of course determine what change,
if any, in total air flow occurs at intermediate damper
positions.

Note that wherever one air handling system is directly
connected with another system, for example, a supply
system connected with an extract system via a
recirculation duct with fixed or variable mixture dampers,
then first proportionally balance the distribution networks
of both systems in turn, finally regulate the total air flow
in both systems, and the proportions of
fresh/exhaust/recirculation air in one combined operation.

d) When the regulation of total air flow is complete, all
branches and terminals on the system will be handling the
required absolute air flow rates within the sum of the
tolerances accumulated during the balancing procedure.

e) The uniformity of air velocity distribution across the face
of electro-static precipitators shall now be checked (see
para. 4.6.2.3.5.e and 4.6.2.3.5.f). Using the same
technique the air flow distribution at ducted heating and
cooling coils may also now be checked.

4.6.2.5.8 Conclusion to Regulation

a) Normally after a satisfactory total air flow has been
established and recorded, a final check shall be made to
ensure that all terminals are in satisfactory balance within
the tolerances specified, by measuring in one continuous
operation the indicated air flow rates at all terminals,
grilles, etc., preferably using one instrument, and by
expressing these measurements as indicated percentages
of design air flow. Where there are more than one type
of terminal on the system, the appropriate factors must be
applied to the readings so that they are all on a
comparable basis. The results obtained are not, of
course, absolute rates of air flow at terminals - they are
merely indicative of the degree of balance between all
outlets. However, taken with a leak-free distribution
system a satisfactory balance at terminals is a proof that
the system has been correctly regulated, and that the
terminals are handling the correct absolute air flow rates,
(Note : do not make random alterations to damper
settings in an attempt to correct any mistakes; any
corrective action will require careful planning to
minimize the amount of rebalancing needed).

BSBTC-01 41

b) After a satisfactory check on system balance, scribe the
position of all manual damper operating arms and,
preferably, lock them.

c) Finally, adjustable louvres and cones on outlets, grilles
and diffusers shall be set to positions predetermined and
specified by the designer.

4.6.2.6 Dual Duct System

a) Dual-duct systems are sometimes designed to handle 85
to 100% of the total systems air supply through the cold
duct and from 40 to 80% through the hot duct. Balance
should be accomplished as follows :

(i) Set all room control thermostats for maximum cooling,
this fully opening the cold air valves.

(ii) The equipment and main ducts should be checked as
outlined in para. 4.5.2.1 and 4.6.2.5

(iii) Determine if the static pressure at the end of the system
(the longest duct run) is at or above the minimum
required for mixing box operation. Proceed to the
extreme end of the system and check the static pressure
drop across the box with an inclined draft gauge or
magnehelic gauge. The drop across the box should equal
or exceed the minimum static pressure recommended by
the manufacturer of the box. About 187 Pa (static
pressure) is common for the mechanical regulator.
Additional pressure is required for the low pressure
distribution system downstream of the box.

(iv) For those units that are not factory preset, dial the proper
setting on the l/s calibrated scale on the mechanical
volume regulator or set the air quantity using the
pneumatic volume regulator or the pressure differential
across the balancing orifice and the manufacturers
calibration curve.

(v) Balance diffusers or grilles on the low pressure side of
the box as described for low pressure systems.

(vi) Change the control settings to full heating and make
certain that the controls and dual-duct boxes function
properly. Spot check the air flow at several diffusers.

(vii) If the designer has taken into account a diversity factor in
selecting the main apparatus, it will not be possible to get
full flow from all boxes simultaneously as outlined
above.

BSBTC-01 42

4.6.2.7 Variable Air Volume System

a) The large variety of variable air volume (VAV) systems
precludes a fixed procedure for balancing. However, a
field balance of this type of system is an absolute
necessity in spite of the many claims for factory-set
terminals, which supposedly make balancing
unnecessary.

b) Of the two major types of VAV system, the first is the
bypass system where a constant volume of air is handled
by the fan with air bypass taking place at the box, and
allowing for variation of air being delivered to the
terminal. This type of system needs no special attention
other than ensuring that the same resistance is installed in
the bypass of the box as through the outlets.

c) The second type of system is true VAV system, wherein
the volume delivered by the fan is varied as the boxes
vary due to load changes. The variation of air volume
can be accomplished by a variable speed drive, an inlet
vane damper, a discharge damper or, in some cases, by
just allowing the static pressure increases to reduce the
air flow rate via the fan curve.

d) The general procedures for balancing this type of system
are as follows :

(i) Determine the required maximum air volume to be
delivered by the supply and return air fans. Diversity of
load usually means the volume will be somewhat less
than the outlet total.

(ii) Obtain fan curves on these units and request information
on surge characteristics from the fan manufacturer.

(iii) If an inlet vortex damper control is to be used, obtain the
fan manufacturers data pertaining to the derating of the
fan when used with the damper. If speed control is used,
obtain information as to maximum and minimum speed
that can be obtained with the drive.

(iv) Determine from the fan manufacturer the minimum and
maximum operating pressures for terminals or VAV
boxes to be used on the project.

(v) Construct a theoretical system curve with approximate
surge area included. The system curve initiates at the
minimum inlet static of the boxes, plus system loss at
minimum flow and terminates at design maximum flow.
The operating range using an inlet vane damper is

BSBTC-01 43
between the surge line intersection with the system curve
and the maximum design flow. When variable speed
control is used, the operating range is between (a) the
minimum speed that can produce the necessary minimum
box static at minimum flow while still remaining in the
fans stable range and (b) the maximum speed necessary
to obtain maximum design flow.

(vi) The terminal boxes must then be positioned to the
proportion of maximum fan air volume to total installed
terminal maximum volume.

(vii) The fan should be set to operate at appropriate design
speed (increase about 5% for a full open inlet vane
damper).

(viii) Static pressure should be checked at various terminals
throughout the system. A sufficient number should be
checked to be representative of the buildings. If a wide
variation in statics is encountered, or a number is below
minimum, then every box should be checked.

(ix) Total air traverse must then be made.

(x) A speed increase must be made if either or both static and
volume are low. If the volume is correct, but the static is
high, the speed must be reduced. If the static is high or
correct, but the volume is low, it is necessary to go over
all the terminals and adjust them to the proper volume.

(xi) Item 7) to 10) should be taken with the return exhaust fan
operating and the system sets on minimum outdoor air.

(xii) Set the outlets to design volume with the VAV box on
maximum flow setting. Verify the minimum flow
setting.

(xiii) Set the return outlets throughout the system.

(xiv) The terminals then should be set to minimum, and the
inlet vane or speed controller adjusted until minimum
static and volume are obtained.

(xv) The temperature control and balancing personnel should
then cooperate in the final location of the sensor for the
static pressure controller. This must be located in the
supply duct far enough from the fan discharge to be truly
representative of the average static pressure in the system.

(xvi) Check the return air fan speed or inlet vane damper to be
sure it is tracking with the supply fan to assure proper
outside air volume.

BSBTC-01 44

(xvii) The system should then be placed on 100% outside air
(weather permitting) and supply and return fans checked
for power and static pressure.

4.6.2.8 Induction System

a) Most induction systems used high velocity air
distribution. Balancing should be accomplished as
follows :

(i) Perform steps outlined under the basic procedures
common to all systems for equipment and main duct
capacities.

(ii) Primary air flow at each terminal unit can be determined
by reading the unit plenum pressure with a portable dry
type of draft gauge or magnehelic gauge and locating the
point on the charts (or curves) of air quantity vs. static
pressure supplied by the unit manufacturer.

(iii) Make a spot check of the air distribution by reading the
first and last unit on each riser. Do not reset these units.
Study these results and then adjust riser dampers to
regulate proper flow in each riser. Normally the high
capacity risers should be cut back to improve the air flow
in the rest of the system.

(iv) Beginning on the floor nearest the main supply duct, start
the first pass around the system, reading and adjusting as
you go. If all unit dampers are open, set the units on the
floor nearest the main supply duct about 10% under
design capacity.

(v) Normally about three complete passes around the entire
system are required for proper adjustment. A final pass
without adjustments must be made to record the end
result.

(vi) The noise level of the system must be reasonable. If the
fan speed is too high, excess static pressure will be
supplied to the induction units and the unit dampers and
riser dampers will have to be closed further in order to
obtain nozzle pressures. The increased pressure drop
across the unit damper and riser damper generates noise
and contributes to a higher room noise level. To provide
the quietest possible operation, the fan speed should be
adjusted to the slowest speed that will provide sufficient
nozzle pressure to all units with the minimum throttling
of all units and riser dampers.

(vii) Normally the flow of water in induction unit coils is

BSBTC-01 45
automatically controlled to adjust room temperature.
Some systems used the primary air source to power the
controls and move a secondary air damper for adjusting
room temperature. In such a case, it is extremely
important that the manufacturers minimum static
pressure in the plenum of each unit be maintained.

(viii) After balancing each supply unit on minimum outdoor
air, reposition to maximum, then take additional power
and static pressure readings in this position. Comparing
power and static pressures in these two positions
immediately indicates any changes necessary in the return
system to accomplish the design requirements.

(ix) Adjust the air terminal outlets for a proper distribution
pattern. Make a final trim of air balance after the
building is occupied and in normal use.

4.6.2.9 Extract System

The extract system can be balanced the same way as supply
system, making modifications as necessary.

4.6.3 Refrigeration Systems

4.6.3.1 General

Testing & commissioning of refrigeration system will normally
be carried out by a skilled and experienced person but the
following points need careful observations.

Essential features are described in four parts :

(i) Reciprocating Compressor Systems
See para. 4.6.3.2.

(ii) Centrifugal Compressor Systems
See para. 4.6.3.3.

(iii) Absorption Systems
See para. 4.6.3.4.

(iv) Screw Compressor Systems
See para. 4.6.3.5.

4.6.3.1.1. System Cleanliness

a) The chilled water, and the condenser water systems
should be flushed through to clean them, generally
following the procedures given in para. 4.5.1.1.

Isolate items which are particularly sensitive to dirt,

BSBTC-01 46
including shell and tube evaporators and condensers,
pumps and spray nozzles and automatic water valves.
Where appropriate, remove strainer screens, cooling
tower basins, tanks and other equipment which may have
accumulated deposits during manufacturing or
installation, and shall also be isolated and flushed
independently.

b) Check the following items for cleanliness.

(i) Air intake screens;

(ii) Fan chambers of condensers and cooling towers;

(iii) Fan internals;

(iv) External heat exchange surfaces of air-cooled condensers,
evaporative condensers and cooling towers;

(v) Sensing elements;

(vi) Cooling tower basins, evaporative condenser tanks and
chilled water tanks;

(vii) Compressor, motor and drive;

(viii) Safety and control devices;

(ix) Drains and overflows.

4.6.3.1.2 State of System

a) Water System

For chilled water and condenser water systems, carry out the T
& C procedures as listed in para. 4.5.1 and 4.6.1 with the
following additions :

Check :

(i) that the cooling tower fill is complete and secured;

(ii) that where chilled water tank is provided the tank lid is
fitted and secured;

(iii) the valved connection (where specified) for blow-down
from cooling towers and evaporative condensers;

(iv) that any splash guards for cooling towers and evaporative
condensers are fitted.

b) Air System

BSBTC-01 47

For air handling systems and any airways associated with the
air-cooled condensers, evaporative condensers and cooling
towers.

Check :

(i) that the airways are clear, including adequate free area of
openings which serve the fans;

(ii) that the condenser heat exchangers are installed correctly
in relation to air flow;

(iii) where applicable, the damper free movement, clearances,
seating, pinning to damper spindles, relative positions of
blades in multi-leaf dampers;

(iv) that dampers are secured in open position with, where
motorized, the actuator disconnected;

(v) the airways including builders work ducts for air-
tightness, noting particular seals at equipment, access
doors, flexible connections, and junction of metal and
builders work ducts.

c) Refrigerant System

Check :

(i) that pipework is complete and secured;

(ii) that the thermostatic expansion valve (or float level
device) are fitted : thermal bulb are correctly fitted and
secured, external equalizer (where appropriate) are fitted;

(iii) that the safety and control devices are fitted : low
pressure cut-out, high pressure cut-out, oil pressure cut-
out (where fitted), and where specified chilled water low
temperature thermostat, low water flow safety device and
any protective solenoid valves;

(iv) that the liquid line strainer, isolating valves as specified,
sight glass with moisture indicator and drier are fitted;

(v) that the suction, discharge and oil pressure gauges with
isolating valves are fitted and isolated from the system;

(vi) that purging and charging connections are fitted;

(vii) that if liquid receiver is provided, the capacity and
associated work to be checked, and where required in the
Particular Specification surveyors certificate to be

BSBTC-01 48
provided before commissioning.

d) Check of Water System Before Filling

Carry out checks as appropriate as described in para. 4.5.1.3.

4.6.3.1.3 Mechanical Checks

a) Fans

Carry out checks as given in para. 4.5.2.4.1

b) Compressors

Check :

(i) the external cleanliness;

(ii) that all components, bolts, fixings, etc., are secured;

(iii) that the compressor shaft is free to rotate;

(iv) the level and plumb of compressor and motor shaft and
slide rails;

(v) the anti-vibration mountings for correct deflection;

(vi) that correct drive is fitted;

(vii) the securing and alignment of pulleys and couplings;

(viii) the belt tension and match;

(ix) that drive guards are fitted, the access for speed
measurement is provided and nipple extension for motor
lubrication is provided;

(x) the correct oil level in compressor;

(xi) that the compressor unloading gear is fitted (if specified);

(xii) any special arrangements for motor cooling; oil cooling
where appropriate;

(xiii) that vibration eliminator and muffler are fitted.

c) Drives

For gear boxes and special mechanical drives pulley/belt, direct
or flexible couplings for compressor or large cooling tower
fans.


BSBTC-01 49
Check :

(i) that the lubrication and pre-lubrication are correct before
starting;

(ii) that drive mounting are secured;

(iii) that all shafts are correctly aligned;

(iv) for free rotation.

4.6.3.1.4. Electrical Checks

a) With all Electrical Supplies Isolated

Check :

(i) the local isolation of motor and control circuits;

(ii) that there are no unshrouded live components within the
panels;

(iii) that the panels and switchgear are clean;

(iv) that the motor and surrounding areas are clean and dry;

(v) that the transit packing has been removed from contactors
and other equipment;

(vi) that there is no mechanical damage to switchgear or water
heaters and that their thermostats are of a suitable range
to operate at ambient temperature (see para. 4.6.1.2);

(vii) that all mechanical checks on the pump and motor of
valve are completed (see para. 4.5.1.4);

(viii) that all the connections are tight on busbars and wirings;

(ix) that the internal links on the starter are correct;

(x) that all the power and control wirings have been
completed in detail to the circuit diagram (paying special
attention to circuits for star-delta connected or specially
wound motors);

(xi) that the fuse ratings are correct;

(xii) that the starter overloads are set correctly in relation to
the motor name-plate full load current;

(xiii) that the dashpots are charged with the correct fluid and
the time adjustments and levels are identical;

BSBTC-01 50

(xiv) that insulation tests on the motor have been performed
satisfactorily;

(xv) that the adjustable thermal cut-outs are set correctly
(check manufacturers test certificates);

(xvi) that all the cover plates are fitted;

(xvii) that the wiring from all safety devices (high pressure cut-
out, low pressure cut-out, etc.) and liquid line solenoid
valve are completed;

(xviii) that the compressor crankcase heater(s) is/are fitted and
the wiring is completed.

b) With Electrical Supplies Available

(i) Check that the declared voltage is available on all supply
phases.

(ii) Where motor powers are substantial or reduced voltage
starting or complex interlocks are involved, the control
circuit logic and the starter operation shall be tested
before the motor is rotated. The supply should first be
isolated; then by the withdrawal of two power fuses or
the disconnection of cables followed by the reinstatement
of supply to the control circuit alone; the control circuit
shall be activated and starter operation observed. In
addition to the compressor starter operation, check for
satisfactory operation of any electrical controls associated
with compressor starter operation such as liquid line
solenoid valve, electrical timing heater on the oil failure
control (in this case check for satisfactory operation and
then temporarily disconnect), and capacity unloading if
initiated electrically.

(iii) Where automatic sequenced starting for the whole of the
refrigeration plant and associated chilled water and
condenser water pumps has been specified, check that the
sequence is correct in order and timing. Adjust timers,
check for clean operation of all contactors, relays and
interlocks. Finally open isolators, reset or reconnect any
device as appropriate, reinstate power connections and
close isolators.

(iv) Where small motors have direct on-line starting and
simple control circuits, the starter operation, etc., should
be checked when first starting the motor.

4.6.3.2. Reciprocating Compressor System


BSBTC-01 51
4.6.3.2.1 Pressure and Leak Testing

Refrigeration system working and test pressures are defined in
BS 4434, Section 7.

a) Factory Assembled Packaged Units

(i) In the case of these units, pressure and leak evacuation
and dehydration and charging, either as a small holding
charge or the full amount, should have been carried out at
the factory.

(ii) Observe pressure gauge readings. If the gauge readings
are unsatisfactory, bearing in mind the amount of charge
supposed to be in the system and the ambient
temperature, the whole programme of pressure testing,
evacuation and charging must be carried out again.

(iii) If the gauge readings are in order, then pressure testing
and evacuation should not be necessary. Where the
system has a holding charge, additional charging will be
necessary. In any case a check leak-test on all joints as
for built-up systems is advised.

b) Built-up Systems

Pressure and leak testing is normally carried out on
completion of the system, before pipework is insulated
and before condenser is filled with water.

(i) Charge the system with a small amount of the refrigerant
being used in the circuit (to, say, a gauge pressure of 1.4
bar). The refrigerant acts as a tracer for leak detection
purposes.

(ii) Charge the entire system to the desired test gauge
pressure (typically 14 bar for R-22 or R502) in
accordance with manufacturers instructions using a
cylinder of dry nitrogen.

(iii) Pressure should be applied to compressor to test the
vulnerable oil lines, etc. Precautions to be made on
applied pressure to avoid damages to the shaft seal.

(iv) Check all joints for leaks by using a soap solution
bubble test. After this, check the entire refrigerant
system for leaks with a halide torch or electronic leak
detector.

Pay particular attention to gasket joints, bolt heads and
nuts, sight glasses, welded joints, parting lines on
castings, gauges and gauge connections, relief valves,

BSBTC-01 52
evaporator and condenser water boxes.

On hermetic units pay particular attention to motor
terminals; on open machines check the shaft seals.

(v) If leaks are discovered the gas and refrigerant in the
system must be exhausted, leaks remedied, and the
system recharged and retested.

(vi) Repair any leaks found on the system. Leaks must not be
repaired while the system is under pressure.

(vii) When the system is found to be leak-free allow to stand
for a minimum of 24 hours under pressure. If no pressure
drop occurs (allowing for effect due to changes in
ambient temperature) the system is ready for evacuation.

(viii) Relieve test pressure to atmosphere, reconnect all lines
and reinstate all items removed or isolated prior to
pressure testing.

4.6.3.2.2 Evacuation and Dehydration

This will be carried out by specialists.

4.6.3.2.3 Associated Air Systems

a) Setting to work and adjusting air handling plant shall be
carried out in accordance with para. 4.5.2 and 4.6.2.

b) For systems employing direct expansion air coolers check
that the commissioning of the main system air
distribution plant has progressed sufficiently through
para. 4.6.2 to enable some measure of heat exchange to
take place at the cooler, to allow limited running of the
refrigeration plant for initial commissioning purposes. It
is preferable that the whole of the para. 4.6.2 work has
been carried out. For air handling plant on the condenser
side of the refrigeration plant, carry out the relevant parts
of para. 4.5.2 and all of para. 4.6.2.4.

4.6.3.2.4 Charging

This will be carried out by specialists.

4.6.3.2.5 Setting to Work and Adjusting

a) Procedures

This section defines the procedures to be carried out in order to
achieve a refrigeration plant working satisfactorily, properly
charged and lubricated, with all controls operating and safety

BSBTC-01 53
devices effective. All procedures as outlined in para. 4.6.3.1
and 4.6.3.2.1 to 4.6.3.2.4 should be completed before
commencing this section. Chilled water and condenser water
systems shall have been checked in accordance with para. 4.5.1
and the setting to work procedures in para. 4.6.1 shall have
been proceeded at least to a point where sufficient water flow is
available to enable full capacity conditions of the refrigeration
plant to be checked.

b) System Checks

Before operating the compressor for the first time (the
compressor will probably have been operated briefly during the
charging operation) a further visual check should be carried out
on the complete system, and in particular all refrigeration safety
controls should be put through their complete cycle of
operation.

(i) Set refrigeration pressure controls in accordance with
manufacturers instructions or ensure that factory settings
have not been disturbed.

Adjust compressor low pressure switch to cut-in
whenever suction pressure rises above desired gauge
setting, with the differential set as wide as possible to
prevent short-cycling.

(Typically, for R-12 : cut-in 2.4, cut-out 1.0 bar
R-22 : cut-in 5.0, cut-out 3.0 bar)

Adjust high pressure switch to recommended gauge
settings.

(Typically, for R-12 : cut-out 12.5 bar
R-22 : cut-out 18.5 bar)

Adjust oil pressure switch to recommended setting.
(Normally usable oil pressure gauge reading minus
suction pressure gauge reading equals usable oil
pressure.) (Typically, cut-in 1.25, cut-out 0.85 bar above
suction pressure.)

Note : On start-up a time delay relay permits
compressor to operate for a predetermined period (usually
above 90 to 120 seconds) while the required oil pressure
differential above suction pressure is being established.

On water chillers check the setting of freeze protection
thermostat (whenever possible this should be fully
checked by immersing the bulb and a thermometer into a
water and ice mixture) in chilled water piping circuit
and/or freeze protection low pressure switch, also the

BSBTC-01 54
operation of evaporator flow switches and back pressure
regulators (where fitted).

(ii) Ensure all sequence and safety interlocks are operating
correctly, i.e. evaporator fans, chilled water pumps,
condenser water pumps, tower fans (or evaporative
condenser fans and pumps, or air-cooled condenser
essential to its operation stop for any reason. Depending
on the wiring arrangements used, some manufacturers
handbooks will show to what extent operation of control
or protective devices can be simulated by electrical
means.

(iii) Make provision for taking refrigerant temperature at a
point as close as possible to the remote bulb of the
thermostatic expansion valve at the evaporator suction
outlet, to enable proper superheat measurement to be
made. The suction pressure should be read at a gauge
installed in the back-set port of the compressor suction
valve and converted to temperature reading using the
refrigerant table. The difference between the
thermometer reading at evaporator suction outlet and the
temperature calculated from suction pressure is the
superheat (most air conditioning installations have
superheat settings of about 5
o
C or 6
o
C).

(iv) This method does not take into account any pressure drop
in the low side of the system (suction lines are normally
designed for 0.07 bar maximum pressure drop). If
abnormal pressure drop is suspected, steps should be
taken to measure it and determine the reason.

(v) Check the condensing system to ensure design air and/or
water quantities at required temperatures are available to
enable desired high side pressure to be maintained.

Particularly check that the condenser water valves are
open and the pressure or temperature actuated automatic
valves (where fitted) are operative.

(vi) Check the associated thermostatic control system as
described in para. 4.6.4.

Set the controlling device (e.g. chilled water, room air, or
return air thermostat, or pressure switch, or humidistat) to
the desired level.

(vii) Immediately prior to commencing a continuous test run
on the refrigeration system.

Check :


BSBTC-01 55
that all refrigerant circuit shut-off valves are in open
position, except for bypass valves; especially ensure that
the condenser liquid line valve is open;

that all chilled water and condenser water circuit valves
are in correct position;

that the compressor suction and discharge valves are
open. Oil, suction and discharge pressure gauge
throttling valves are open;

that the solenoid stop valves of evaporator are working
on magnetic coil control;

that the lubricating oil is visible (at centre, or above) in
sight glass on compressor sump;

that electrical supply has been available to the crankcase
heater and that the heater has been operating. In a cold
plant room a period of at lease one hour of operation
should elapse prior to running to enable the heater to boil
off any refrigerant.

(viii) Depress reset buttons on refrigerant pressure control(s),
oil pressure control and freeze protection thermostat
and/or freeze protection pressure switch.

c) Start-Up

(i) Turn the compressor over several times by hand from the
drive coupling (or vee-belts), and ensure there is free
movement of all rotating parts. Disconnect drive
coupling or vee-belt. Check the correct direction of
motor.

(ii) Start on manual control of the chilled water pump (or
relevant fan) and condenser water pump and cooling
tower fan (or condenser fan or evaporative condenser fan
and pump). If controls are arranged for sequenced auto
start only, proceed straightly to automatic start of the
complete plant.

Correct any operating difficulties before proceeding.

(iii) Start and stop the compressor several times (at about 10
second intervals) and observe :

- the direction of rotation of compressor;

- that motor, drive, and compressor are free from vibration
or undue noise;


BSBTC-01 56
- the motor starting current;

- the oil and refrigerant pressure gauges.

Take care not to exceed permissible starts/hour of
switchgear. On plant with both manual and auto
selection, after two or three successful manual
operations change over to automatic control.

d) Shut-Down

(i) If the plant has auto controls, operate an automatic shut
down. Check that all sequencing and any special shut
down requirements are operated satisfactorily.

(ii) If the plant is arranged for manual control, proceed
through the correct relevant sequence to shut the
complete plant down; observe whether all automatic or
safety features are operated satisfactorily.

(iii) In either case above note whether anything incorrect
occurs during the shut down cycle (such as noise,
vibration, or unexpected pressure variation).

e) Running-In

When all of para 4.6.3.2.5.a to 4.6.3.2.5.d have been
satisfactorily completed the complete system should be
placed in operation and allowed to run normally for at
least 72 hours. It is recommended that the installation be
continuously supervised by a competent person for at
least half of this running-in period.

The oil level in the compressor must be watched closely
during this entire period. The compressor must not under
any circumstances be allowed to run short of oil.

During the running-in period, try to ensure that there will
be sufficient load to keep the plant running. This may
mean the provision of an artificial load. Check and
observe the following features, and adjust if necessary. A
log book for recording all operation information at every
hour must be made available.

(i) Superheat setting of the thermostatic expansion valve
using the method given in para. 4.6.3.2.5.b.iii. Checks
must be carried out under conditions approximating to
design conditions (i.e. average or maximum load, but not
light load) and satisfactory condenser pressure; otherwise
deceptive values of superheat will occur due to incorrect
operating conditions and not incorrect setting of the valve
control.

BSBTC-01 57

Do not alter superheat setting until it is certain that the
reset of the system is operating satisfactorily. If under
normal operating conditions incorrect values of superheat
are found, gradual adjustment of the control setting (as
given in the manufacturers instructions) and rechecking
of the superheat value should be made.

(ii) All operating temperatures and pressures (in refrigerant
cycle and chilled water and condenser water circuits) are
under normal running conditions. Refrigerant flows at
sight glasses. Bubbles indicate refrigerant shortage and
possible leak.

(iii) Amperage and voltage readings of all motors, any
sparking at commutator or slip rings should be recorded.

(iv) Check the system for refrigerant leaks. This should be
done at least twice during the running-in period. When
these checks have been made and the plant is running
satisfactorily and steadily, check the operation and
calibration of control and protection devices.

(v) The operation and control of the refrigeration plant by the
primary control device (thermostat, etc.). The actual
control of the condition (temperature, etc.) by the device
will be checked as given in para. 4.6.4. This check
concerns the ability of the device to stop and start the
refrigeration plant in the required manner. This operation
should be achieved by a gradual reduction of the cooling
load. This should be done solely so that there is ample
time to note any extended sequence of events. When the
refrigeration plant has stopped, load can be gradually
increased, so as to observe the automatic starting up
sequence. The cycle can be repeated more quickly, but
there is no merit in changing the load more quickly than
would occur naturally. An unnaturally rapid change of
load could occur too quickly for the satisfactory operation
of protection devices and damage the plant.

(vi) During this load changing procedure, the satisfactory
operation of the liquid line solenoid valve, compressor
capacity control system, unloaded compressor start-up,
and automatic pump down, where these facilities are
specified, should be observed.

(vii) Low pressure cut-out. Close the liquid line shut off valve
(isolating valve on liquid receiver or cause the liquid line
solenoid valve to close). The compressor will then
reduce pressure in the evaporator. Check that the low
pressure cut-out operates at the suction pressure
recommended. Watch the suction gauge carefully, do not

BSBTC-01 58
allow the suction pressure (particularly with water
chillers) to fall more than about 0.1 bare below the
recommended setting. Open the valve and check the
pressure at which compressor cuts in. Isolating valves
should be opened and closed as slowly as possible.

(viii) High pressure cut-out. Gradually reduce the flow of the
condensing medium (by closing a valve on condenser
water circuit, or restricting the air flow to or from the air-
cooled condenser). This will cause the condenser
pressure to rise. Check that the high pressure cut-out
operates at the condenser pressure recommended. Watch
the pressure gauge carefully, do not allow the condenser
pressure to rise appreciably above the recommended
setting. Slowly restore flow of condensing medium and
check the pressure at which compressor cuts in (with
manual rest it will be necessary to depress reset button).

(ix) Condenser pressure control, where fitted. During this
period if possible note the operation of condenser
pressure control under either naturally occurring low
external temperature conditions (at night perhaps) or
where possible simulated conditions by say on a multi-
compressor plant feeding the whole of the condensing
capacity to one machine. The aim is to provide
conditions which would lead to a drop in condenser
pressure and then establish that the control devices
operate to maintain condenser pressure steadily at the
correct value.

(x) Evaporator pressure regulating valve, where fitted.
Reduce the cooling load, so that suction pressure tends to
drop. Observe the evaporator pressure (if a special gauge
has not been fitted, fit one temporarily at the evaporator
on the evaporator side of the valve); this should not fall
below the required value, even though the suction
pressure drops to cut-out level.

(xi) With the assistance of manufacturers recommendation
check the operation of any other special control or
operating devices such as low water temperature control,
low water flow control, or hot-gas by-pass circuit
controls. Where any device is installed for protection of
the plant, care must be exercised when checking so that
should the protective device fail to operate, the plant is
not allowed to continue to run and damage itself.

(xii) Condenser pressure against condenser temperature. If
pressure is excessive this indicates presence of air or
other non-condensable gases. Stop the plant, allow the
condenser to cool, then purge. Restart the plant, recheck,
and re-purge if necessary.

BSBTC-01 59

(xiii) All mechanical equipment should be checked for excess
heat, noise and vibration.

f) First Inspection after Running-In

This cannot be carried out until the plant has been in
operation for at least 72 hours.

During the running-in period lubricating oil will have had
time to accumulate in any low spots, or oil loops, as at
the bottom of double-riser piping circuits. Hence, the
amount of oil to be retained in the system outside of the
compressor should be stabilized by this time, and the
level in compressor should be relatively constant. In
addition, scale or foreign material in refrigerant lines and
water circuits should have been loosened and collected in
strainers.

By the end of the running-in period any improper
adjustments or sources of potential trouble should be
apparent.

(i) Recheck the compressor oil level. If low, wait further
three or four hours to see that returning oil does not
restore proper level. If level remains low, further
lubricating oil should be added to maintain correct level.
Ensure that the compressor crankcase heater is working
so that oil level is not high due to refrigerant distilling
into the oil.

(ii) Remove test gauges and plug tappings.

(iii) With compressor stopped, check the compressor shaft
seal for refrigerant leakage.

(iv) Check the alignment and lubrication of compressor
motor. Check and tighten as necessary the holding-down
bolts.

(v) Check the drive belts for proper tension and alignment.

(vi) Check the dryer. If there is presence of appreciable
moisture, change the dryer.

g) Final Inspection after Running-In

This should be carried out after the system has been in
operation for about one week (not before).

(i) Drain the compressor crankcase and clean the interior
with approved cleaner.

BSBTC-01 60

(ii) Recharge the compressor with new clean compressor oil
which is of exact type and grade specified by the
manufacturer.

(iii) Tighten bolts in coupling between compressor motor (or
adjust belt drive as necessary).

(iv) Change the dryer element.

4.6.3.3 Centrifugal Compressor System

The complete plant must prior to running, have been pressure
and leak tested, evacuated and dehydrated, and the system
charged with refrigerant and lubricating oils by the specialists.
The charging operation is normally carried out by the
specialists on site. In addition, cleanliness, stage of system and
mechanical and electrical components must be checked.

On open type centrifugal ensure transmission lined up in
accordance with manufacturers instructions.

Check :

(i) that evaporator and condenser shells are correctly
levelled;

(ii) that all flanged connections are correctly aligned and
tightened, with proper gaskets in place;

(iii) that liquid line and float valve assembly are complete;

(iv) that vibration isolation to compressor is provided in
accordance with manufacturers recommendations;

(v) that motor cooling connections are complete;

(vi) that the purge unit and small-bore accessory piping are
completed, including cooling water connections where
specified;

(vii) that oil sump accessories and connections are installed;

(viii) that control gauges and tubing are completed;

(ix) that temperature control bulbs are correctly located, space
between bulb and well is filled and suitable heat
conducting fluid, and capillary tubes are free from
damage or distortion.

4.6.3.3.1 Pressure and Leak Testing


BSBTC-01 61
Refrigeration system working and test pressures are defined in
General Specification (Clause 20.08 - Pressure Testing for
Refrigerant Systems).

a) Factory Assembled Units

These are factory pressure and leak tested, often
insulated, and delivered to site with a holding charge of
refrigerant (usually only R-12 and R-113 systems).

(i) Observe pressure gauge readings. If gauges register zero
unit may have been damaged in transit and holding
charge lost, in which case the whole programme of
pressure and leak testing must be carried out again.

(ii) If gauge readings are in order (according to
manufacturers figures) then a leak test should be carried
out around all joints. Alternatively, units may be
despatched under vacuum and in this case the
manufacturers recommended procedures should be
followed.

b) Site-assembled Units

Pressure and leak testing should be carried out on
completion of the installation, before the unit and the
immediately adjacent pipework connections are insulated,
and before condenser or evaporator is finally filled with
water.

A cylinder of dry nitrogen and a small amount of
refrigerant of a type recommended by the unit
manufacturer should be used to pressure test the system.
Refrigerant R-12 is frequently used for this purpose and
also serves as a tracer for leak detection, although the
working refrigerant may be of a different type.

(i) Where the required test pressures exceed the allowable
pressures on certain items, remove or isolate these
components. Ensure the system is suitably sealed to
enable the pressure testing to be carried out.

(ii) Where the purge unit is subjected to a higher operating
pressure than the remainder of unit, it should be isolated
and tested separately at a higher pressure.

(iii) Charge the purge unit to the desired test pressure with
proper type of refrigerant in accordance with
manufacturers instructions.

(iv) Check the entire purge unit for leaks using a halide torch
or electronic leak detector. Tap all joints with a mallet

BSBTC-01 62
and remove any flux that may be adhering to them.

(v) Repair any leaks and retest the unit. Leaks must not be
repaired while the system is under pressure.

(vi) On satisfactory completion of test, relieve test pressure
(by opening valves in connecting pipework to main unit)
and remove charging apparatus.

(vii) Reinstate any items previously removed or isolated.

(viii) To charge and leak test the entire unit, first connect a
cylinder of refrigerant as recommended by the unit
manufacturer to the charging valve (R-12 is typically
used for leak testing).

(ix) Charge enough refrigerant into the system to produce a
pressure as recommended by the unit manufacturer for
leak test purposes (typically 0.14 bar gauge pressure for
R-11 system).

(x) Close the charging valve and remove the refrigerant
charging apparatus.

(xi) Connect a cylinder of dry nitrogen to the charging valve
on the unit and charge to the desired test gauge pressure
(typically 1.0 bar for R-11 system). Suitable nitrogen
injection pressure reducing valve is fitted.

(xii) Close the charging valve and remove the charging
equipment.

(xiii) Check all joints for leaks by using a soap solution
bubble test. After this, check the entire refrigerant
system for leaks with a halide torch or electronic leak
detector.

Pay particular attention to gasket joints, bolt heads and
nuts, sight glasses, welded joints, parting lines on
castings, gauges and gauge connections, relief valves,
evaporator and condenser water boxes.

On hermetic units pay particular attention to motor
terminals; on open machines check the shaft seals.

(xiv) Repair any leaks found on the system. Leaks must not be
repaired while the system is under pressure.

(xv) When the system is found to be leak-free allow to stand
for a minimum of 24 hours under pressure. If no pressure
drop occurs (allowing for effect due to changes in
ambient temperature) the system is ready for evacuation.

BSBTC-01 63

(xvi) Relieve test pressure to atmosphere, reconnect all lines
and reinstate all items removed or isolated prior to
pressure testing.

Note :Some manufacturers may permit R-11 and R-113
machines to be pressurized using the purge pump. R-114
machines may be pressurized with dry nitrogen, a typical
test gauge pressure being 2.2 bar.

4.6.3.3.2 Evacuation

This will be carried out by specialists.

4.6.3.3.3 Associated Air Systems

Check in accordance with para. 4.6.3.2.3

4.6.3.3.4 Charging

The procedure to be adopted will vary according to the make of
unit, type of refrigerant and will be carried out by specialists.

4.6.3.3.5 Setting to Work and Adjusting

a) Procedures

After satisfactory completion of procedures in para.
4.6.3.1. and 4.6.3.3.1. to 4.6.3.3.4, and before operating
the centrifugal compressor for the first time, a further
visual check shall be carried out on the complete system.

The chilled water and condenser water systems must have
been thoroughly checked in accordance with para. 4.5.1
and 4.6.1, and be ready for operation. For this section to
be carried out completely, some load on the chilled water
plant (probably at least 50 per cent) is necessary.

b) System Checks

(i) Controls

With all electrical supplies isolated, check wire
connections for tightness and fuses for correct size.

With centrifugal compressor motor electrically isolated
by removal of power fuses (or by disconnection of power
leads), check that chilled water pumps, condenser water
pumps, cooling tower fans, and centrifugal refrigerant
plant oil pump operate in the sequence required, rotate in
the proper direction, and that flow rates and pressures are
set to the required levels.

BSBTC-01 64

Ensure that centrifugal compressor motor will be
locked-out if other equipment essential to its operation
stops for any reason.

Set each control and safety device in accordance with
manufacturers instructions, or ensure that factory
settings are correct and have not been disturbed. The
complete control system shall be checked out generally in
accordance with para. 4.6.4.

Check the settings and the functional operation (by
raising and lowering the temperature of water at sensing
element if necessary) of following items as appropriate to
system under consideration :

- Load sensing device, usually chilled water thermostat.

- Inlet guide vane operator.

- Load limit relay.

- Pneumatic/electric switches.

- Oil temperature control (this may require check on
operation of sump cooling water solenoid valve and sump
heater).

- Oil pressure relief valve.

- Oil filter pressure cut-out switch.

- Low pressure oil cut-out switch.

- High pressure oil cut-out switch.

- Chilled water low temperature cut-out.

- Refrigerant low temperature cut-out.

- Cooling tower thermostat and condensing water controls.

Also fitted may be :

- Time delay relay on inlet vane operator.

- Vane closed switch.

- Time delay relay on oil pump (to prolong running on shut
down cycle).

- Timers in main motor starter.

BSBTC-01 65

- Thrust bearing and transmission bearing high temperature
cut-out thermostat (on compressor).

- Timer (to limit number of starts per hour) and recycling
device.

- Motor winding high temperature cut-out switch.

- Flow switches (chilled and/or condenser water).

Check for satisfactory operation of pilot lights and reset
buttons.

(ii) Purge Unit

Compressor purge system

Check :

- the oil levels in compressor sump and oil separator
sections;

- the operation of high pressure control;

- the operation of temperature control and purge heater;

- the alignment of motor and compressor shafts, drive belt
adjustment, and lubricate compressor motor bearings in
accordance with manufacturers instructions;

- that the system isolating valves are in correct positions
(open/closed).

(iii) Thermal purge system

Check in accordance with manufacturers instructions
and ensure all valves are in correct position
(open/closed).

(iv) Start-Up

Ensure all electrical switches and starters are in off
position and supplies are isolated. Replace any fuses or
leads removed during para. 4.6.3.3.5.b.i.

Ensure all water valves are in proper position.

Place chilled water pump, condenser water pump, cooling
tower fan, refrigeration machine oil pump and purge
system starters in auto position and close isolators.


BSBTC-01 66
Start the chilled water and condenser water pumps and
cooling tower fans.

Energize the control circuits.

Start the oil pump and allow the main compressor to run.
Check the compressor impeller rotation. If incorrect, stop
immediately, electrically isolate, and reverse any two of
the three phase connections. Recheck.

Start the purge system.

- Compressor type. Energize the purge heater and after 30
minutes, start purge compressor, or in accordance with
manufacturers instructions. The longer in time is better.

- Thermal type. Start in accordance with manufacturers
instructions.

The centrifugal refrigeration system now should be in full
operation.

(v) Shut-Down

Stop the compressor and then the chilled water pumps,
condenser water pumps and cooling tower fans in
sequence.

Listen for any unusual sounds from compressor or
transmission housing during coast-down period.

Check that the operation of oil pump continues until time
delay relay causes it to stop.

(vi) Running-In

Restart plant in accordance with para. 4.6.3.3.5.iv.

Check the oil pressure and temperature.

Check the operations of refrigerant agitator solenoid
valves (where fitted) in relation to vane motor crank
angle.

Adjust the motor overload trip mechanism in accordance
with the instructions of the compressor and start
manufacturers.

Caution :

- Do not allow motor to operate in overloaded
condition beyond the time permitted by the manufacture

BSBTC-01 67
(typically 60 minutes at 105 per cent of full load
amperage).

Adjust low limit relay to manufacturers instructions.

Check for satisfactory operation of low temperature
control.

Check for satisfactory operation of refrigerant low
temperature cut-out.

Check the operation of high pressure cut-out (if necessary
isolated switch and use metered air supply).

Take gauge and other readings and compare with design
figures, typically :

- Evaporator pressure.

- Condenser pressure (measure water temperature if
necessary).

- Purge drum pressure.

- Oil sump temperature.

- Oil level.

- Chilled water and condenser water temperatures.

4.6.3.4 Absorption System

The absorption refrigeration machine usually factory assembled
though, certain necessary items may be installed on site. Prior
to running, the unit must be pressure and leak tested, evacuated
and charged with primary refrigerant (usually lithium bromide
solution), lubricating oils and chemicals.

The charging operations are usually carried out on site. In
addition, cleanliness, stage of system and mechanical and
electrical components must be checked.

Check :

(i) that the unit is correctly installed and levelled;

(ii) that the chilled water and condenser water circuits are
complete and are ready to operate. Water treatment is
available if specified;

(iii) that the steam and condense, or hot water piping system
are complete with adequate pressure gauges,

BSBTC-01 68
thermometers, and test points;

for steam piping system: pressure relief valve and safety
valve are correctly set; trapping arrangements are
satisfactory; control valve is correctly installed;

for hot water piping system: control valve is correctly
installed;

(iv) that steam, or hot water, is available at rated
pressure/temperature;

(v) that auxiliary water piping and drains are completed (as
may be required for pump motor, cooling and lubrication
during start-up periods);

(vi) that all electrical wiring, to starters, motors, and controls
are completed;

(vii) that pneumatic controls (where used) are installed,
pneumatic piping is completed and tested, air pressure is
available;

(viii) that all gauges and thermometers (or test points) are
installed on water inlets and outlets to evaporator,
absorber and condenser;

(ix) that dry nitrogen and refrigerant (general R-12) are
available for pressure and leak testing (when carried out
on site);

(x) that lithium bromide solution, chemicals and lubricating
oils are available for charging, together with necessary
equipment.

(xi) that for the system to be operated and properly
commissioned it is usually necessary to have at least 75
per cent of the cooling load available.

(xii) In addition, in conjunction with the manufacturers
representative, ensure that phase sequence of power
supply is checked and that connections are properly made
before hermetic pumps are operated (some types of
machines).

Note : The absorption unit is usually shipped to site as a factory
assembled package, having been evacuated, leak tested,
and charge with dry nitrogen under a slight positive
pressure. Various items of accessory equipment such as
purge pumps, control panels, etc., may be installed on
site. In this case, final leak testing, evacuation, charging,
and start-up of the unit are usually carried out by, or

BSBTC-01 69
under the supervision of the manufacturers
representative.

Alternatively, the absorption unit may be factory
assembled, pressure tested and evacuated and shipped to
site under a vacuum and in this case it is important that
none of the unit valves are tampered with as a loss of
vacuum may result.

4.6.3.4.1 Site Leak Testing

a) Absorption Unit Shell

(i) Isolate the purge unit (manual valve between purge drum
and purge pump).

(ii) Charge a small amount of R-12 (typically 2 kg) into the
unit through the access valve on concentrator sump.
(Some manufacturers specify R-12 as suitable for leak
testing a dry system only and state that it must not be
admitted to the system after charging with lithium
bromide solution.)

(iii) Raise the gauge pressure within the unit to test figure
(typically 0.75 bar) with dry nitrogen.

(iv) Check for leaks with halide torch or electronic leak
detector. In particular, check all welds, joints, float
valves and around hermetic pumps.

(v) Correct or repair any leaks, and retest as necessary.

b) Purge System

(i) Ensure gauge unit is isolated.

(ii) Close the gas ballast valve on the purge pump.

(iii) Connect vacuum hose to the purge pump exhaust fitting,
place open end of hose in glass container of water and
start the pump.

(iv) Purge system is leak free if no bubbles appear in water
after about 10 minutes operation. Pay attention to the
power supply interruption, otherwise water may be
sucked into the system.

(v) If the result is satisfactory, slightly open the gas ballast
valve until bubbles appear in water.

(vi) Remove test equipment. Purge system is now ready for
service.

BSBTC-01 70

4.6.3.4.2 Evacuation

This will be carried out by specialists.

4.6.3.4.3 Associated Air Systems

Check in accordance with para. 4.6.3.2.3

4.6.3.4.4 Charging

This will be carried out by specialists.

4.6.3.4.5 Setting to Work and Adjusting

a) Procedures

After satisfactory completion of procedures in para.
4.6.3.1. and 4.6.3.4. to 4.6.3.4.iv, 4.6.3.4.4 and before
operating the absorption machine for the first time, a
further visual check should be carried out on the
complete system.

The chilled water and condenser water systems must have
been thoroughly checked in accordance with para. 4.5.1
and 4.6.1 and be ready for operation. The heating fluid
(steam or hot water) circuit must have been similarly
checked and be ready for operation.

b) System Checks

With absorption machine solution pumps electrically
isolated, or with their power fuses withdrawn, check that
chilled water pumps, condenser water pumps and cooling
tower fans operate in the sequence required, rotate in the
proper direction, and that flow rates and pressures are set
to the required levels.

Ensure that solution pumps will be locked-out if other
equipment essential to their operation stops for any
reason.

Set each control and safety device in accordance with
manufacturers instructions or ensure that factory settings
are correct and have not been disturbed. The complete
control system should be checked out generally in
accordance with para. 4.6.4.

Check the settings and the functional operation (by
raising and lowering the temperature of water at sensing
element if necessary) of the following items as
appropriate to the system under consideration:

BSBTC-01 71

(i) Load controller, usually chilled water thermostat.

(ii) Operation of automatic control valve on heating medium.
Ensure medium is at the desired temperature and
pressure.

c) Pneumatic/electric switches (on pneumatic systems) and
set in accordance with manufacturers instructions.

(i) High temperature control, where fitted. (Typically
factory set to cut out at 24
o
C and cut-in at 18
o
C
refrigerant water temperature.)

(ii) Time delay relay for high temperature control.

(iii) Note: This is typically set to hold the control
incorporative for the first five minutes of machine
operation which permits the machine to start when the
refrigerant water is initially above the control setting.

(iv) Low temperature control. (Typically factory set to cut-
out at 2
o
C and cut-in at 6
o
C refrigerant water
temperature.)

(v) Chilled water flow switch (where fitted).

(vi) Condenser water flow switch (where fitted).

(vii) Cooling tower thermostat. Ensure raising and lowering
of set point starts and stops tower fans.

(viii) Condensing water thermostat.

(ix) Operation of condensing water control valve.

(x) Setting of motor temperature control protectors.

Some types of machine require refrigerant water for
lubrication of refrigerant and solution pumps. On these
machines the refrigerant sump is dry at start-up and must
be filled with distilled water in accordance with the
manufacturers instructions. Air must not be allowed to
enter the system.

(xi) Check operation of float switch controlling minimum
operating level of refrigerant (after filling of sump where
applicable).

d) Start-Up

(i) Ensure all electrical switches and starters are n off

BSBTC-01 72
position and supplies are isolated. Replace any fuses
removed during para. 4.6.3.4.5.b.

(ii) Place chilled water pump, condenser water pump and
cooling tower fan starters in auto position and close
isolators.

(iii) Ensure all water valves are in proper position.

(iv) Open the heating fluid isolating valve.

(v) Start the chilled water and condenser water pumps, and
cooling tower fans.

(vi) Start the absorption refrigeration machine and place
solution pumps in operation (i.e. evaporator, concentrator
and absorber pumps).

Note : The system not should be operative. The
manufacturers engineer will not normally make final
system adjustments, including placing the absorbent
regulating valves in the correct position and sealing to
prevent readjustment by unauthorized personnel.

e) Shut-Down

The sequence of operation of the dilution or shut-down
cycle (which prevents crystallization when the solution
cools to ambient temperature) must be checked. This
dilution sycle normally allows the unit pumps to operate
under the control of a time delay relay.

(i) Stop the absorption refrigeration machine. The
condenser pumps and the cooling tower fans should stop
immediately and the heating control valve should close.

(ii) Check that the time delay relay permits the chilled water
pumps and the solution pumps to continue operation for
the period of time specified by the manufacturer
(typically about seven minutes).

f) Running-In

With purge unit operational allow the system to operate
for approximately eight hours and at the same time
observe the performance and make any necessary
adjustments. Ensure purge unit operates satisfactorily.

(Purge unit may be of vacuum pump type operated by
manual on/off switch, or of the automatic hermetic type
which functions continuously while the absorption
machine is running.)

BSBTC-01 73

After approximately eight hours, stop the unit, then
isolate, clean and replace strainers. Return isolating
valves to normal position.

If unit operation is satisfactory, arrange for final
insulation of those parts normally left incomplete until
system has been commissioned (e.g. chilled water boxes
and where applicable refrigerant sump, piping and motor
coating/lubricant lines).

4.6.3.5 Screw Compressor System

The procedure described is for a factory assembled screw
compressor water chiller, which has been pressure and leak
test, evacuated and dehydrated at the manufacturers works,
and transported to site as a complete assembly, with operating
chargers of refrigerant and lubricating oil.

Commissioning should be carried out in accordance with the
manufacturers instructions.

a) Check :

(i) that the unit refrigerant and oil charges are intact. If
unsatisfactory, arrange for checks and repair leaks;
pressure test, dehydrate and recharge by the
manufacturer.

(ii) that the unit is installed in accordance with
manufacturers recommendations and designers
specification.

(iii) that the unit is correctly levelled.

(iv) that vibration isolators (where specified) are provided in
accordance with designers instructions.

(v) that the unit is free of water and oil leaks.

(vi) that expansion valve bulbs, and any other temperature or
pressure sensing bulbs are correctly located with capillary
tubes free from damage or distortion.

(vii) that pipeline tappings (with fixed or test gauges) for
pressure and temperature measurements are available on
chilled water and condenser water circuits.

b) by competent person that the electric control wiring (and
pneumatic control systems where specified) is completed
and in accordance with para. 4.6.4. In particular :


BSBTC-01 74
(i) Set remote overload trips for compressor and oil pump
motor (typically 110 to 115 per cent full load current).

(ii) Set current load limiting device (where provided) to
allow operation at 100 per cent load without tripping
(typical setting within range 100 to 109 per cent).

(iii) Set any starter time delays, as with start-delta starters.

Note :The procedures in the following para. 4.6.3.5.1,
4.6.3.5.2, 4.6.3.5.4 should be adopted when the initial
check on unit refrigerant and oil factory charges has
indicated loss of pressure during transit from the factory
and/or damage to unit.

4.6.3.5.1 Pressure and Leak Testing

Pressure and leak testing should be carried out on completion
of the installation, before the unit and the immediately adjacent
pipework connections are insulated, and before the condenser
or evaporator is finally filled with water.

A cylinder of dry nitrogen and a small amount of refrigerant of
a type recommended by the unit manufacturer should be used
to pressure test the system. Refrigerant R-22 is commonly used
for this purpose and also serves as a tracer for leak detection
purpose.

a) Charge a small amount of refrigerant into the low side of
the system, using convenient valve to achieve a gauge
pressure of about 2.0 bar. (It is essential to use low side
charging where compressor discharge line is fitted with
check valve.)

b) Close the charging valve and remove the charging
apparatus.

c) Carry out preliminary leak test using halide torch or
electronic leak detector.

d) Connect a cylinder of dry nitrogen to the charging valve
and charge to the desired test gauge pressure (typically 15
bar for R-22).

e) Close the charging valve and remove the charging
apparatus.

f) Thoroughly re-check the entire system for leaks.

g) Repair any leaks and retest the system. Leaks must not
be repaired while the system is under pressure.


BSBTC-01 75
h) When the system is found to be leak-free, allow to stand
for a minimum of 24 hours under pressure. If no pressure
drop occurs (allowing for effects due to changes in
ambient temperature) the system is ready for evacuation.

i) Depressurize the system to atmospheric pressure (where
discharge check valve is fitted, the high side after the
check valve must be separately depressurized).

4.6.3.5.2. Evacuation and Dehydration

This will be carried out by specialists.

4.6.3.5.3. Associated Air Systems

Check in accordance with para. 4.6.3.2.3.

4.6.3.5.4. Charging (R-22 System)

This will be carried out by specialists.

4.6.3.5.5. Setting to Work and Adjusting

a) Procedure

After satisfactory completion of procedures in para.
4.6.3.1. and 4.6.3.5.1 to 4.6.3.5.4, and before operating
the compressor continuously for the first time, a further
visual check should be carried out on the complete
system.

b) System Checks

(i) With compressor motor power circuit electrically
isolated, set all refrigeration controls in accordance with
design engineers instructions, or ensure that factory
settings are correct and have not been disturbed. All
safety controls should be put through their complete cycle
of operation.

(ii) The number of controls and adjustments are more
complex than is usual with reciprocating machines. As a
guide, typical controls are listed below. Control settings
should be in accordance with the design specification;
safety settings should be based on manufacturers
recommendations.

- Pressure switches
- High pressure cut-out
- Low pressure pump down
- Low pressure cut-out
- Low pressure unload

BSBTC-01 76
- High pressure oil cut-out
- Oil failure switch

- Temperature switches
- Freeze-up
- Low water temperature
- Oil sump temperature heater control
- Low oil sump temperature heater control

- Timing relays
- Oil failure relay
- Oil pump coast-down relay
- Compressor loading time delay
- Oil circulating time delay
- Anti-recycling relay
- Flow switches
- Set to cut-in and cut-out at flow rates recommended by -
design engineer.
- Set temperature/load controller in accordance with
designers brief and para. 4.6.4. (preliminary settings
only).

- Other adjustments
- Certain types and sizes of screw machine may have -
adjustments relating to hydraulic unloader cams, which
should be set by manufacturers representative.
- The hydraulic unloader level time should be set by
manufacturers representative.
- This includes :Fast unload maximum to
minimum load
Minimum load to maximum load
Maximum load to minimum load

(iii) With compressor power circuit energized check :

- the oil pump for correct rotation.

- the compressor for correct rotation (momentary start).
Do not let the compressor attained the full running speed,
since if running backwards, high speed operation may
cause damage.

- These checks should be carried out strictly in accordance
with manufacturers recommendations.

c) Start-Up

Manual sequence

(i) Switch on heater in oil sump and wait until recommended
oil temperature (typically 43
o
C) is attained.


BSBTC-01 77
Note :Manufacturer may recommended warm-up period
of 24 hours with compressor power circuit isolated.

(ii) Energize compressor control circuits.

(iii) Start those items of equipment required to operate by
sequence interlock before compressor is started, e.g.
evaporator fans, chilled water and condenser water
pumps, cooling tower fans, etc. Ensure compressor will
be lock-out if items essential to its operation stop for
any reason.

Check all safety controls and reset.

(iv) Restore power to compressor power circuits, and start the
compressor in accordance with manufacturers
instructions, ensuring oil pump operative, compressor
unloading slide valve moves to fully unloaded position,
and other items working correctly by observation of pilot
lights. If oil pressure does not reach the required pressure
the system will automatically shut down (in
approximately five seconds). Controls must be reset
and/or fault rectified before proceeding.

(v) With oil pump operative and correct pressure available,
the compressor will start fully unloaded after the oil
circulating time delay.

Check for satisfactory operation of all pilot lights.
Ensure items such as hot gas injection solenoid valve
(when fitted), small (or single) expansion valve and side
oil injection solenoids are operating correctly.

(vi) On completion of warm-up cycle (two minutes loading
time delay) check that the main oil injection solenoid
valve and the temperature/load controller are activated,
and fast unload solenoid valve is de-energized.

(vii) Check the compressor loads as required and pilot light
operative when loading. On units with dual expansion
valves, ensure that the large expansion valve operates as
loading passes 33 per cent. Check and adjust superheat
settings to design requirements (typically within range 10
to 14
o
C).

(viii) Check the oil gauge pressure and level at 100 per cent
capacity (typical 2.0 bar with level to bottom of upper
sight glass in sump).

(ix) Set the temperature/load controller in accordance with
designers brief (final settings).


BSBTC-01 78
d) Shut-Down

Automatic Sequence

(i) Check that the large expansion valve (if provided) closes
at approximately 26 per cent capacity (may be activated
by cam switch in relation to unloader slide valve travel).

(ii) When the temperature of chilled water reaches the setting
of low temperature switch check that shut-down (which
normally takes place below 10 per cent load) occurs as
follows :

Small expansion valve (if provided) is de-energized.

Compressor shuts down at required suction pressure
(typically a gauge pressure of 5.4 bar).

Main and side oil injection valves are de-energized.

Temperature/load controller is locked out and all
appropriate pilot lights go out.

(iii) Oil re-circulating pump stops after 10 seconds (held in by
oil pump coast down relay) to complete automatic shut-
down.

(iv) Ensure that the anti-recycle relay prevents compressor
from restarting until preset time (15 minutes minimum)
after low water temperature switch cuts back in.

e) Running-In

Note: These checks are carried out after approximately
1000 hours of operation.

(i) Change the refrigerant filter dryer(s) if moisture shows
wet or if the desired pressure differential exceeded
(typically a gauge pressure of 0.27 bar).

(ii) Take oil sample and submit to compressor manufacturer
for analysis.

(iii) Check cam settings, superheat and sub-cooling
temperature, unloader speed.

4.6.3.6 Cooling Tower

Field testing cooling towers is a demanding and difficult task.
However, certain general criteria that set up the ground rules
for proper testing & commissioning of cooling towers are as
described below.

BSBTC-01 79

4.6.3.6.1 Conditions for Testing & Commissioning

There are certain conditions that require to be fulfilled before T
& C can commence. Ensure that

a) the water system serving the tower has been thoroughly
cleaned, preliminary checks and setting to work and
balancing have been carried out in accordance with para.
4.5.1 and 4.6.1;

b) the fan serving the cooling tower has been set to work in
accordance with para. 4.5.2 and 4.6.2 noting any
permanent obstruction and removing all foreign
obstructions;

c) the interior fills of the tower are properly cleaned and free
from foreign materials such as scale, algae or fur;

d) the water level in the tower basin is maintained at the
proper level, making sure by visual check of the basin
sump that the centrifugal action during full flow does not
cause any entrainment of air which may cause pump
cavitation;

e) all valves except balancing valves in the water system are
in full open position;

f) provisions for facilities to determine make-up and
blowdown water flow rates are available, if not valve off
both.

4.6.3.6.2 Test Method

The actual test method consists of the following steps :-

(i) Determine volume of water in the tower, volume of
make-up water and volume of blowdown water.

(ii) Record temperature of make-up water.

(iii) Measure the volume and temperature of make-up water at
the point of entry to the system.

(iv) Measure the volume and temperature of blowdown water
at the point of discharge from system.

(v) Measure inlet and outlet dry and wet bulb temperatures.

(vi) Use entering & leaving wet bulb temperatures to
determine the tower performance against design.


BSBTC-01 80
(vii) Use entering and leaving dry and wet bulb temperatures
to determine the rate of evaporation involved.

(viii) Measure wet and dry bulb temperatures between 1 and
1.5 metre from the tower on all sides. These readings
should be taken half-way between the base and the top of
the inlet louvre at not more than 1.5 metre spacing
horizontally and averaged out.

(ix) Note any unusual inlet conditions, wind velocity and
wind direction at the time of test.

(x) Take readings continually with a minimum of time lapse
between readings.

(xi) If the first test indicates a tower deficiency, perform two
additional tests to verify the original readings.

4.6.4 Control Systems

4.6.4.1 General

The testing and commissioning of Central Control and
Monitoring System (CCMS) and Building Automation System
(BAS) will be carried out by specialists and are not covered by
these guidelines. Control systems as defined herein relate to
on the plant control systems, including pressure/temperature
sensing points, motorized valves, dampers, etc. with which the
CCMS/BAS may interface.

It is essential that all wirings within the control panel have been
checked for loose connections, correct terminations and
compliance with wiring diagrams. In addition it is also assured
that functional checks to ensure that all interlocking and
sequencing have been carried out in accordance with the
requirements and specifications.

It is also critical that the procedures described elsewhere
relating to the regulation of air, water, refrigeration systems and
any other connected equipment have been carried out prior to
commissioning the control system.

4.6.4.1.1. Preliminary Checks

This section is common to all types of system. Before
attempting to set up automatic controls it should be ascertained
that the following requirements are satisfied :

(i) All electrical supplies are isolated.

(ii) All control components are installed in accordance with
specified requirements and manufacturers instructions,

BSBTC-01 81
e.g., that control valves are correctly positioned and
ported and that temperature and humidity elements suit
the temperature ranges involved.

(iii) ALL SAFETY DEVICES INCLUDING CIRCUIT
INTERLOCKS AND CUT-OUTS ARE CORRECTLY
INSERTED INTO THE OVER-ALL OPERATIONAL
PLAN AND WILL EFFECTIVELY CARRY OUT THE
PURPOSE INTENDED.

(iv) All sensing elements are located in a position which will
give good representation of the controlled variable and
are not subject to extraneous influence.

(v) Measuring instruments have been calibrated against
certified standards.

4.6.4.1.2. Operating Checks

Checks :

(i) that a full rated flow of the controlled media, the pump
and fan pressures are within design tolerances
immediately prior to setting-up;

(ii) that the input temperature of the controlled media and the
pressure at the input of the controlled device at full
design flow condition are each within specified design
limits and that the pressure difference across the device is
to design requirements.

Note: In the case of variable fluid flow the pressure
available at any particular controlled device will tend to
vary in relation to demands at other points of regulation
within the system. There will also be some variation of
the temperature of fluid available at the inlet of the
device particularly at low-flow conditions.

Hence, checks must be made to ensure that at any point in
the system the fluid to be controlled is not only available
within the specified limits of temperature and pressure
but that the controlled device continues to provide the
degree of control required throughout the range of
variations in flow and pressure to which the system may
be subjected.

(iii) that the movement of the controlled device matches with
the travel of the actuator. For example, examine damper-
actuator assemblies.

4.6.4.1.3. Electricity Supply and Wiring


BSBTC-01 82
The following checks are to be made before switching on the
electricity supply :

(i) that the wiring has been installed to the required standard
regulations and is in accordance with the control
equipment manufacturers requirements. Special care
should be taken to ensure that the cable possesses suitable
physical and electrical characteristics and that the
earthing suits the equipment;

(ii) that all connections are in accordance with the relevant
wiring diagrams supplied;

(iii) that the electrical supply at the point of distribution for
the control system is correct and that suitably rated fuses
are available.

4.6.4.1.4. Connection to electrical Supply

Switch on the electrical supply.

4.6.4.2 Pneumatic Control System

4.6.4.2.1. Check-Out, Calibration and Setting-Up Procedure

The procedure divides the system into principal component
parts as follows :

(i) Compressed air supply.

(ii) Valve, damper and other actuators.

(iii) Controllers.

4.6.4.2.2 Compressed Air Supply

Note: It is assumed firstly that air leakage checks have been
made progressively during the construction period in
accordance with the specified requirements. It is further
assumed that air compressing equipment has been subjected to
mechanical and electrical checks in accordance with the
manufacturers instructions.

Check where applicable :

The pipework and connections have been installed in
accordance with relevant control system drawings.

a) the compressed air receiver(s) relief valve(s) is/are
correctly set and operating. After cooler to be checked if
fitted.


BSBTC-01 83
b) The action of the pressure switch initiating a compressor
start is correct and that the compressor(s) subsequently
effectively recharge the system.

c) The duty-changeover system for the compressors is
functioning correctly.

d) The air receiver is at the required pressure. Survey
certificate to be provided before operation.

e) The air drying apparatus is properly installed, prepared
and operative.

This may involve one or more of the following
supplementary checks :

(i) that the electrical supply is available to any refrigeration
equipment specifically intended for dehumidification of
the control air supply and that this equipment is
functioning correctly;

(ii) that the compressed air delivered is below the specified
dew point temperature required at any point in the
system;

(iii) that any chemical dryer is ready to accept air through at
least one cell;

(iv) that where cooling water is used it is available, flowing at
the required rate and at an acceptable temperature.

f) Visually, at the nearest convenient pressure reducing set,
for residual cleanliness and freedom from oil and water in
the delivered air.

4.6.4.2.3. Valve, Damper and Other Actuators

Check that the actuator provides the correct position of the
controlled device with zero pressure input.

4.6.4.2.4 Setting-Up Action

a) Install a suitable test pressure gauge in the branch line
output from the controller, near to the actuator(s).

b) Check the operating range adjustment where fitted.

c) Check the start point adjustment where fitted.

d) Vary the line air pressure to the actuator and check that
the pressure at which the actuator starts to move
corresponds with the desired start point pressure.

BSBTC-01 84

e) Vary the line air pressure until the actuator has moved the
device through the required travel and check that the air
pressure change is in accordance with the control
sequence.

Note: Throughout this procedure check for smooth and
regular movement of the actuator and device. In the case
of valve control, this calls for attention to gland packings
and in the case of dampers that they do not bind at the
bearings or are otherwise mechanically unsound. (See
Checks in para. 4.5.2.2).

4.6.4.2.5 Transmitters/Controllers

a) Transmitters, where installed, should be checked for
correct output and/or calibrated as necessary in
accordance with the manufacturers instructions.

b) Check that the action of the controller is correct for the
application (direct or reverse-acting).

c) Set the throttling range or proportional band of the
controller to the design value. For two and three term
controllers, these settings should suit the characteristics
of the plant. In the case of controllers which are to be
reset by other source pressures, ensure that the reset input
pressure and setting is correct for the calibration
procedure for that particular instrument.

d) Ensure that a suitable test pressure gauge is installed in
the branch line output from the controller.

e) Move the set-point of the controller so that it is
equivalent to the condition measured at the detector.

It may be necessary to stablize conditions at the detector
during this procedure.

f) Calibrate the instrument so that a gauge pressure equal to
the start point gauge pressure plus half the operating
range is note on the test gauge. (For example : range 20
to 100 kPa (0.2 to 1.0 bar), set at 60 kPa (0.6 bar)).
Manufacturers may sometimes recommend slight
variations on this.

g) With proportional controllers, incremental movements of
the set-point should give proportional movement of the
final control device in the required direction. Check that
the total movement of the set-point to give full movement
of the control device corresponds to the proportional
band setting.

BSBTC-01 85

h) Check the operation of any pressure switches and
pneumatic relays which may form part of the control
systems, etc., by applying a suitably varied control
pressure.

Adjust the set-point to the specified desired value.

i) Cancel any measures that may have been taken to
stabilize the conditions at the detector thus returning the
plant ready for normal working. Adjust the throttling
range of controllers to obtain the minimum proportional
band consistent with stable control.

j) Any interlocking, travel limit or overriding devices
should then be checked to ensure that the overall
sequence of control is achieved.

4.6.4.2.6. Plant Operation

Following the T & C procedures, the design conditions should
be achieved and maintained for a suitable period of
observation. If the conditions cannot be achieved or
maintained, then a check on the final control devices should be
carried out to ascertain that maximum correction has been
applied. If this is satisfied an investigation beyond the control
system is indicated.

4.6.4.3 Electrical and Electronic Control Systems

4.6.4.3.1 Check-Out, Calibration and Setting-Up Procedure

The procedure divides the system into principal component
parts as follows :

(i) Valve, damper and other actuators

(ii) Controllers and detectors

4.6.4.3.2 Actuating Units

Check :

(i) that the actuator has the correct movement so that it will
give the required travel of the final control device;

(ii) that any linkage adjustments for rotation lift or close-off
have been suitably set;

(iii) that in the case of spring return motors being fitted, the
position assumed upon interruption of the power supply
is correct;

BSBTC-01 86

(iv) that all action intended to succeed an interruption of
power, and the subsequent reinstatement, are faithfully
followed;

(v) that throughout this procedure there is smooth and regular
movement of the actuating motor and regulator.

Note: In the case of valve control, this calls for attention
to gland packings and in the case of dampers that they do
not bind at the bearings or are otherwise mechanically
unsound. (See Mechanical Checks in para. 4.5.1.4).

4.6.4.3.3 Transmitters

Calibrate as follows :

(i) Move the set-point of the controller so that it is
equivalent to the condition measured at the detector.

It may be necessary to stabilize the conditions at the
detector during this procedure.

(ii) Set the proportional band of the controller to the design
value. For two and three term controllers, these settings
should suit the characteristics of the plant.

In the case of controllers which are to be reset by other
source signals arrange for second, or other stage, signal
inputs shall be connected in accordance with the
calibration procedure for that particular instrument. For
example, adjust Authority settings as required and
where applicable.

(iii) With proportional controllers, incremental movements of
the set-point should give proportional movement of the
final control device in the required direction. Check that
the total movement of the set-point to give full movement
of the control device corresponds to the proportional
band setting.

(iv) In the case of the two-position control check that the
switching action is correct and any internal heaters are
disconnected during calibration.

(v) Adjust the set-point to the specified desired value.

(vi) Make Dead Zone adjustment where applicable.

(vii) Cancel any measures that may have been taken to
stabilize the conditions at the detector thus returning the
plant ready for normal working.

BSBTC-01 87

(viii) Adjust proportional bands of controllers to attain the
minimum deviation consistent with stable control. In the
case of timed-two-position and floating control systems,
set the design differential and where applicable, the time
interval which is consistent with stable control and the
minimum deviation.

4.6.4.3.4. Sequence Control

Any interlocking or overriding devices should then be checked
to ensure that the overall sequence of control is achieved.

4.6.4.3.5. Plant Operation

Following the T & C procedures, the design conditions should
be achieved and maintained for a suitable period of
observation. If the conditions cannot be achieved or
maintained, then a check on the final control devices should be
carried out to ascertain that maximum correction has been
applied. If this is satisfied an investigation beyond the control
system is indicated.

4.6.5. Performance Tests

After the system has been commissioned, its performance shall
be observed and checked under normal conditions, both winter
and summer while making all required adjustments to
automatic controls, air dampers, registers, fans etc. until all
performance requirements are met.

4.6.6 Noise and Sound Tests

4.6.6.1 The present state of the art does not permit tests to
determine if equipment is operating with desired sound
levels. Field tests can determine only sound pressure
levels, and equipment ratings are almost always in terms
of sound power levels. Until new techniques are
developed, the commissioning engineer can determine
only if sound pressure levels are within desired limits
and, if not, determine which equipment, systems or
components are the source of excessive or disturbing
transmission.

4.6.6.2 When carrying out the testing and commissioning
procedure, one should make reference to the Technical
Memorandum for the assessment of noise issued by the
Environmental Protection Department for the
determination of the accceptable noise level; such as the
Area Sensitivity Ratings(ASRs) and Acceptable Noise
Levels(ANLs). In determining allowable HVAC
equipment noise, A-weighted sound levels, dBA, are

BSBTC-01 88
used when carrying out all field tests as A-weighting of
the sound level meter is becoming the standard
measurement relating to the probable subjective
assessment of the loudness level of sound of any
frequency or intensity.

4.6.6.3 Most field sound measuring instruments and techniques
yield an accuracy of 2 dB, which is about the smallest
difference in sound pressure level that the average person
can discern. A reasonable tolerance for sound criteria is
5 dB, and, if 35 dB(A) were to be considered as the
maximum allowable noise, the design engineer should
realistically specify 30 dB(A).

4.6.6.4 The measured sound level of any location is a
combination of all sound sources present including sound
generated by HVAC equipment as well as sound from
other sources such as plumbing systems and fixtures,
elevators, light ballasts and outside noises. In testing
HVAC systems for sound, all sources of sound from
other than HVAC equipment are considered as
background or ambient noise.

4.6.6.5 Background sound measurements generally have to be
made when : (1) specification requires determination of
sound levels from HVAC equipment only as opposed to
the sound level in a space not exceeding certain specified
level, (2) sound level in the space exceeds desirable level,
in which case it is necessary to determine what part of the
noise is contributed by the HVAC system and (3) for
residential locations and spaces where there is little
significant background noise during the evening hours
and where generally low allowable noise levels are
specified or desired.

4.6.6.6 Ideally, the building should be completed and ready for
occupancy before sound level tests are taken. All spaces
in which readings will be taken should be furnished with
drapes, carpeting and furniture, as these affect the room
absorption and the subjective quality of the sound. In
actual practice, since most tests have to be conducted
before the space is completely finished and furnished for
final occupancy, the commissioning engineer must make
some allowances. Since furnishings increase the
absorption coefficient and reduce sound pressure level by
around 4 dB, the following guidelines should suffice for
measurements made in unfurnished spaces. If sound
pressure level is 5 dB or more greater than specified or
desired criterion, it can be assumed that criterion will not
be met even with the increased absorption provided by
furnishings. If sound pressure level of 0-4 dB greater
than specified or desired criterion, recheck when the

BSBTC-01 89
room is furnished to determine compliance.

4.6.6.7 Follow this general procedure :

a) Obtain a complete set of accurate, as-built drawings and
specifications, including duct and piping details. Review
specifications to determine sound and vibration criteria
and any special instructions for testing.

b) Visually check the system for noncompliance with plans
and specifications, obvious errors and poor workmanship.
Turn the system on for audible check. Listen for noise
and vibration, especially duct leads and loose fittings that
can be the source of disturbing noise.

c) Adjust and balance equipment as described in other
sections of this procedure so final acoustical tests are
made with the system as it will actually be operating. It
is desirable to perform acoustical tests for both summer
and winter operation, but where this is not practical,
make tests for the summer operating mode as it usually
has the potential for higher sound levels. Test must be
made for all mechanical equipment and systems
including standby. (For equipment or systems that can
function concurrently but cannot be so operated at the
time of tests, separate sound measurements must be taken
and added in accordance with Table 2 to determine
compliance with desired criteria.)

d) Check calibration of instruments.

e) Measure sound levels in all areas as required, combining
measurements as indicated in item c) above if equipment
or systems must be operated separately. Before final
measurements are made in any particular area, survey the
area using an A-weighted scale reading dB(A) to
determine the location of the highest sound pressure
level. Indicate this location on a testing form and use it
for test measurements. Restrict the preliminary survey to
determine location of test measurements to areas that can
be occupied by standing or sitting personnel.

For example, measurements would not be made directly
in front of a diffuser located in the ceiling, but they would
be made as close to the diffuser as standing or sitting
personnel might be situated. In the absence of specified
sound criteria, the commissioning engineer shall measure
sound pressure levels in all occupied spaces to determine
any sources of excessive or disturbing noise.

f) Determine if background noise measurements must be
made.

BSBTC-01 90

(i) If specification requires determination of sound pressure
level from HVAC equipment only, it will be necessary to
take background noise readings to determine the
background correction factor as indicated in Table 1.

(ii) If specification requires compliance with a specific noise
level or criteria (for example : sound pressure levels in
office areas shall not exceed 43 dB(A)), ambient noise
measurements are needed to be made only if the noise
level in any area exceeds the specified value. Use Table
1 to determine that portion of noise contributed by
HVAC system.

(iii) For residential locations and areas requiring very low
noise levels such as sound recording studios and
locations that will be used during the normally quieter
evening hours, it is usually desirable to make sound
measurements in the evening and/or take ambient noise
measurements. As shown in Tables 1 and 2, if two sound
pressure levels are 10 dB or more apart, the lower sound
level has no significant effect on the overall or combined
sound level. But if they are 3 dB or less apart there is a
very significant interaction. If the background noise is
only 3 dBA lower than the combined noise, then the
background noise is equal to the noise as generated by
HVAC equipment.

Table 1 - Background Correction (dB)
Decibel
difference
between sound
level when air
conditioning
equipment is
operating (total
level) and when it
is not operating
(background
level)
0 1 2 3 4 7 10
Decibel to be
subtracted from
total sound level
in order to get the
sound level due
to air-
conditioning
equipment alone
over
10
7 4 3 2 1 0.5





BSBTC-01 91
Table 2 Summation of Noise Levels
Difference in dB(A) between
two noise levels being summed
Amount in dB(A) to add to the
higher noise level

0 to 0.5 3.0

1.0 to 1.5 2.5

2.0to 3.0 2.0

3.5 to 4.5 1.5

5.0 to 7.0 1.0

7.5 to 12 0.5

more than 12.0 0



Note: When using Table 2 noise levels should be summed in a
pairwise fashion and the final total rounded to the nearest
whole dB(A), with values of 0.5 or more being rounded
upwards.


4.6.7 Vibration Tests

4.6.7.1 Testing for vibration is necessary to assure that (1)
equipment is operating with satisfactory vibration levels
and (2) objectionable vibration and noise are not
transmitted to the building structure. Although these two
factors are inter-related, they are not necessarily
interdependent. A different solution is required for each,
and it is essential to test both the isolation system and the
vibration levels of the equipment.

4.6.7.2 the general order of steps in vibration testing are as
follows :

a) Make a visual check of all equipment for obvious errors
that must be corrected immediately.

b) Make sure all isolation systems are free floating and not
short circuited by any obstruction between equipment to
equipment base and building structure.

c) Turn on the system for audible check for any obviously
rough operation. Check bearing with stethoscope.
Bearing check is especially important because bearings
can become defective in transit and/or if equipment was
not properly stored and maintained. Defective bearings
should be replaced immediately to avoid damage to shaft
and other components.

d) Equipment and systems should be adjusted and balanced
as described in other sections of this procedure so final
vibration tests are made on equipment as it will actually
be operating.

e) Test equipment vibration.


BSBTC-01 92
4.6.7.3 The following steps should be taken to assure that
vibration isolation systems are functioning properly :

a) Assure that system is free floating by applying
unbalanced load, which should cause system to move
freely and easily. On floor mounted equipment, check
that there are no obstructions between base or foundation
and building structure that would case transmission while
still permitting equipment to rock relatively free because
of the application of unbalance force. On suspended
equipment check that hanger rods are not touching the
vibrating plant. Rigid connections such as pipes and
ducts can prohibit mounts from functioning properly by
providing a flanking path for transfer of vibration to the
structure, etc. Note the fact that the system is free
floating does not mean that the isolators are functioning
properly. For example, a 500 rpm fan installed on
isolators having a natural frequency of 500 rpm could be
free floating but would actually be in resonance, resulting
in transmission to the building and excessive movement.

b) Determine if isolators are properly adjusted and
providing desired isolation efficiency. All isolators
supporting a piece of equipment should have
approximately the same deflection, i.e. compressed the
same under the weight of equipment. If not, they have
been improperly adjusted, installed or selected; this
should be corrected immediately. The only accurate
check of isolation efficiency is to compare vibration
measurements of equipment operating with isolators to
measurements of equipment operating without isolators.
As such tests are usually impractical, it is best to check
isolator deflection to determine if deflection is as
specified, and if specified or desired isolation efficiency
is being provided.

4.6.7.4 While it is easy to determine the deflection of spring
mounts by measuring with a ruler the difference between
the free heights (information as shown on submittal
drawings or available from manufacturer), such
measurements are at best difficult with most pad or
rubber mounts. Furthermore, most pad and rubber
mounts do not lend themselves to accurate determination
of natural frequency as a function of deflection. For such
mounts, the most practical approach is to check that there
is no excessive vibration of base and no noticeable or
objectionable vibration transmission to the building
structure.

4.6.7.5 If isolators are in the 90% efficiency range and there is
transmission to the building structure, the equipment is
operating very roughly or there is a flanking path of

BSBTC-01 93
transmission such as connected piping or obstruction
under the base.

4.6.7.6 It is possible that secondary vibrations transmitted from
isolators may coincide with the resonant frequency of the
structural floor slab on or from which the equipment is
supported or suspended. In such cases, the solution is
that the secondary frequency transmitted to the structure
must be altered which may be achieved by adjustment of
the isolator deflection.


5. Calibrated Equipment

5.1 The Contractor shall supply calibrated equipment as stipulated in the
Specification of the Contract for the inspection, measuring and
testing of the installation. The equipment shall be calibrated by
laboratories accredited by the Hong Kong Laboratory Accreditation
Scheme (HKLAS) or other recognised accredited laboratories..

5.2 A list of equipment proposed to be used for T & C must be available
prior to commissioning the work. All equipment that requires
periodic calibration shall have this carried out before the work is
commenced and data sheets on such test instrument indicating the
manufacturers name, model number, latest date of calibration and
correction factors shall be submitted to the Project BSE for approval.
If any item requires re-checking the accuracy because of the time that
has elapsed since the previous calibration, this shall be carried out
prior to commencing the work.

5.3 The suggested minimum items of instruments & accessories
necessary to carry out the objectives are :

a) Inclined manometer calibrated in not less than 0.1 Pa (0.0005
in. of water) divisions.

b) Combined inclined and vertical manometer 0-2000 Pa (0-10 in.
of water) is generally the most useful.

c) Pitot tubes (usually 450-mm (18-in.) and 1200-mm (48-in.)
long tube cover most balancing requirements).

d) A tachometer, which should be the high quality, direct contact,
self-timing type.

e) Clamp-on ampere meter with voltage scales.

f) Deflecting vane anemometer.

g) Rotating vane anemometer.

h) Thermal-type (hot-wire) anemometer.

BSBTC-01 94

i) Dial and glass stem thermometers.

j) Pressure gauges (Manifold & Single)

k) Test wells

l) Pressure tappings




Note: * Delete if not appropriate

Appendix A
Building Services Branch, ArchSD Page 1 of 14 Filecode: SR61.doc
FORM NO. BS/SR.061 Revision Date:15 March 2000
Issue Date: 3 March 2000

Testing and Commissioning Certificate
on Air-conditioning, Refrigeration, Ventilation and Control Systems


Part 1 : Details of Project

1.1 Project title (with location) :

1.2 * P.W.P. / Project No. :

1.3 *Contract/sub-contract/Quotation No. :

1.4 * Contractor/Sub-contractor :

1.5 PBSE :

1.6 PBSI :


Part 2 : Declaration

2.1 I certify that the Air-conditioning, Refrigeration, Ventilation and Control
Systems as specified in the Contract/Sub-contract/Quotation at the above
location has been inspected, tested and commissioned in accordance with
this procedure and/or any other procedures agreed between the PBSE and
the Contractor. The results are satisfactory in the aspects as mentioned in
Part 3 and/or as recorded in Part 4 of this Certificate, except as indicated
in the COMMENTS items.

2.2 I also certify that site tests have been performed in accordance with the
requirements set out in Appendix A of this procedure and that the results
are satisfactory. A record of the tests has been prepared and submitted to
the project BSE.


Signature of Contractors Representative

Full Name of Contractors Representative

Designation of Contractors Representative

Name and Stamp of Contractor

Date

Note : This certificate must be signed by a person authorized by the Firm/Company.
* Delete if not applicable
Appendix A
Building Services Branch, ArchSD Page 2 of 14 Filecode: SR61.doc
FORM NO. BS/SR.061 Revision Date:15 March 2000
Issue Date: 3 March 2000


Items tested/
checked by
Contractor
Items witnessed
by
PBSE/PBSI


Part 3. Items Inspected and Tested



3.1 The General Requirements as indicated in the T & C
procedure have been complied with.
*Yes/No/N.A. *Yes/No/N.A.

3.2 Precommissioning Checks

3.2.1 Water Distribution System

a) The system has been properly cleaned, flushed and
filled with water.
*Yes/No/N.A. *Yes/No/N.A.

b) The equipment associated with the system has
undergone the mechanical and electrical checks and the
results are satisfactory.
*Yes/No/N.A. *Yes/No/N.A.

3.2.2 Air Distribution System

a) The system has been been properly cleaned and usually
checked for air tightness.
*Yes/No *Yes/No

b) The equipment associated with the system has
undergone mechanical and electrical checks and the
results are satisfactory.
*Yes/No *Yes/No

3.3 Setting to Work & Balancing

3.3.1 Water Distribution System

a) The water pumps have been commissioned in
accordance with this procedure and the pumps are
operating satisfactorily.
*Yes/No/N.A. *Yes/No/N.A.

b) The water flow rates of the system have been regulated
and balanced in accordance with this procedure. The
results are satisfactory meeting the specified
requirements.
*Yes/No/N.A. *Yes/No/N.A.

3.3.2 Air Distribution System

a) The filters have been commissioned according to
*this/manufacturers procedure and the results are
satisfactory, meeting the specified requirements.
*Yes/No/N.A. *Yes/No/N.A.






Tested / Checked by Signature
(Name of Contractors Representative)

Witnessed by Signature(s)
(Name(s) of *PBSE/*PBSI))

Appendix A
Building Services Branch, ArchSD Page 3 of 14 Filecode: SR61.doc
FORM NO. BS/SR.061 Revision Date:15 March 2000
Issue Date: 3 March 2000


Items tested/
checked by
Contractor
Items witnessed
by
PBSE/PBSI


b) The fans have been commissioned according to
*this/manufacturers procedure and the results are
satisfactory meeting the specified requirements.
*Yes/No/N.A. *Yes/No/N.A.

c) The air flow rates of the system have been regulated in
accordance with this procedure and the system is
delivering the designed air volumes at the terminal
outlets.
*Yes/No/N.A. *Yes/No/N.A.

3.3.3 Refrigeration Systems

a) The system has been satisfactorily cleaned and the
equipment has undergone electrical and mechanical
checks.
*Yes/No *Yes/No

b) Reciprocating Compressor System

(i) The refrigeration system has been commissioned by a
specialist in accordance with the manufacturers
recommendations.
*Yes/No/N.A. *Yes/No/N.A.

(ii) The refrigeration system has satisfactorily completed
the running-in period as specified in this procedure and
all necessary adjustments/ repairs/ replacements have
been carried out.
*Yes/No/N.A. *Yes/No/N.A.

c) Centrifugal Compressor System

(i) The refrigeration system has been commissioned by a
specialist in accordance with the manufacturers
recommendations.
*Yes/No/N.A. *Yes/No/N.A.

(ii) The refrigeration system has satisfactorily completed
the running-in period as specified in this procedure and
all necessary adjustments/ repairs/ replacements have
been carried out.
*Yes/No/N.A. *Yes/No/N.A.
(d) Absorption System

(i) The refrigeration system has been commissioned by a
specialist in accordance with the manufacturers
recommendations.
*Yes/No/N.A. *Yes/No/N.A.

(ii) The refrigeration system has satisfactorily completed
the running-in period as specified in this procedure and
all necessary adjustments/ repairs/ replacements have
been carried out.
*Yes/No/N.A. *Yes/No/N.A.



Tested / Checked by Signature
(Name of Contractors Representative)

Witnessed by Signature(s)
(Name(s) of *PBSE/*PBSI))
Appendix A
Building Services Branch, ArchSD Page 4 of 14 Filecode: SR61.doc
FORM NO. BS/SR.061 Revision Date:15 March 2000
Issue Date: 3 March 2000


Items tested/
checked by
Contractor
Items witnessed
by
PBSE/PBSI


(e) Screw Compressor System

(i) The refrigeration system has been commissioned by a
specialist in accordance with the manufacturers
recommendations.
*Yes/No/N.A. *Yes/No/N.A.

(ii) The refrigeration system has satisfactorily completed
the run-in period as specified in this procedure and all
necessary adjustments/ repairs/ replacements have been
carried out.
*Yes/No/N.A. *Yes/No/N.A.

(f) Cooling Tower

The cooling tower(s) of the installation *has/have been
field tested in accordance with this procedure and the
results are satisfactory, meeting the specified
requirements.
*Yes/No/N.A. *Yes/No/N.A.

3.3.4 Control System

(a) All the safety devices including circuit interlocks and
cut-outs have been checked for correct installation and
operation.
*Yes/No *Yes/No

(b) The complete pneumatic and/or electric control system
*has/have been checked and commissioned in
accordance with this procedure.
*Yes/No *Yes/No

3.3.5 Noise and Sound Tests

The noise and sound levels in areas as specified have
been checked in accordance with this procedure and are
found in compliance with the Specification.
*Yes/No/N.A. *Yes/No/N.A.

3.3.6 Vibration Tests

The vibration tests for equipment as specified have
been carried out in accordance with this procedure and
the results are satisfactory, meeting the specified
requirements.
*Yes/No/N.A. *Yes/No/N.A.











Tested / Checked by Signature
(Name of Contractors Representative)

Witnessed by Signature(s)
(Name(s) of *PBSE/*PBSI))
Appendix A
Building Services Branch, ArchSD Page 5 of 14 Filecode: SR61.doc
FORM NO. BS/SR.061 Revision Date:15 March 2000
Issue Date: 3 March 2000


Items tested/
checked by
Contractor
Items witnessed
by
PBSE/PBSI


3.3.7 Performance Test

(i) A full-load performance test has been carried out and
the results which were recorded separately were found
meeting the specified requirements.
*Yes/No/N.A. *Yes/No/N.A.

(ii) a full-load performance test has NOT been carried out
but it will be carried out during the free-maintenance
period.
*Yes/No/N.A. *Yes/No/N.A.








































Tested / Checked by Signature
(Name of Contractors Representative)

Witnessed by Signature(s)
(Name(s) of *PBSE/*PBSI))
Appendix A
Building Services Branch, ArchSD Page 6 of 14 Filecode: SR61.doc
FORM NO. BS/SR.061 Revision Date:15 March 2000
Issue Date: 3 March 2000


Items tested/
checked by
Contractor
Items witnessed
by
PBSE/PBSI


3.4 Comments *Yes/No/N.A. *Yes/No/N.A.

















































Tested / Checked by Signature
(Name of Contractors Representative)

Witnessed by Signature(s)
(Name(s) of BSB Staff)
Appendix A
Building Services Branch, ArchSD Page 7 of 14 Filecode: SR61.doc
FORM NO. BS/SR.061 Revision Date:15 March 2000
Issue Date: 3 March 2000

Part 4 : Test Record attached to the Test Certificate

4.1 General

Plant performance can be substantiated only when the test data have been recorded and
validated against the design data. Proforma for recording such data can be found in the
succeeding pages and these should be properly filled in before submission to the designers with
any relevant comments related to site conditions.

4.2 Packaged Water Chillers

Location : No. : Design Test

Machine Type

Refrigerant Type

Capacity (kW)

Leaving Chilled Water Temperature (
o
C)

Leaving Chilled Water Temperature
control Limited (
o
C)

Entering Chilled Water Temperature (
o
C)

Chilled Water Quantity (l/s)

Entering Condenser Water Temperature (
o
C)

Leaving Condenser Water Temperature (
o
C)

Condenser Water Quantity (l/s)

Evaporator Fouling Factor

Condenser Fouling Factor

Evaporator Working Pressure (kPa)

Evaporator Test Pressure (kPa)

Evaporator Entering Temperature (
o
C)

Evaporator Leaving Temperature (
o
C)

Condenser Working Pressure (kPa)

Condenser Test Pressure (kPa)




Tested / Checked by Signature
(Name of Contractors Representative)

Witnessed by Signature(s)
(Name(s) of *PBSE/*PBSI))
Appendix A
Building Services Branch, ArchSD Page 8 of 14 Filecode: SR61.doc
FORM NO. BS/SR.061 Revision Date:15 March 2000
Issue Date: 3 March 2000

Location : No. : Design Test

Condenser Entering Temperature (
o
C)

Condenser Leaving Temperature (
o
C)

Motor Type

Motor Speed (rev/s)

Motor Full-load Condition (amp. & volt)

Motor No-load Condition (amp. & volt)

Drive Arrangement

Machine Mountings

Supply Voltage (V)

4.3 Air-Cooled Condensing Sets

Location : No. : Design Test

Compressor

Refrigerant Type

Capacity (kW)

Saturated Suction Temperature (
o
C)

Saturated Discharge Temperature (
o
C)

Total Heat Rejected (kW)

Compressor Absorbed Power (kW)

Motor Nameplate Rating (kW)

Motor Type

Motor Speed (rev/s)

Drive

Motor Full-load Condition (amp. & volt)

Motor No-load Condition (amp. & volt)

Supply Voltage (V)




Tested / Checked by Signature
(Name of Contractors Representative)

Witnessed by Signature(s)
(Name(s) of *PBSE/*PBSI))
Appendix A
Building Services Branch, ArchSD Page 9 of 14 Filecode: SR61.doc
FORM NO. BS/SR.061 Revision Date:15 March 2000
Issue Date: 3 March 2000

Location : No. : Design Test

Condenser

Capacity (kW)

Condensing Temperature (
o
C)

Summer Design External Dry Bulb (
o
C)

Sub-cooling (
o
C)

Head Pressure Control Method

Fan Type

Drive

Motor Type

Motor Nameplate Rating (kW)

Motor Speed (rev/s)

Motor Full-load Condition (amp. & volt)

Motor No-load Condition (amp. & volt)

Supply Voltage (V)

4.4 Cooling Towers

Location : No. : Design Test

Type :

Cooling Capacity (kW)

Summer Design Wet Bulb Temperature (
o
C)

Altitude above Sea Level (m)

Entering Dry Bulb Temperature (
o
C)

Entering Wet Bulb Temperature (
o
C)

Leaving Dry Bulb Temperature (
o
C)

Leaving Wet Bulb Temperature (
o
C)

Make-up water Quantity (l/s)



Tested / Checked by Signature
(Name of Contractors Representative)

Witnessed by Signature(s)
(Name(s) of *PBSE/*PBSI))
Appendix A
Building Services Branch, ArchSD Page 10 of 14 Filecode: SR61.doc
FORM NO. BS/SR.061 Revision Date:15 March 2000
Issue Date: 3 March 2000

Location : No. : Design Test

Constant Bleed Water Quantity (l/s)

Cooling Water Flow Rate (l/s)

Cooling Water Entering Temperature (
o
C)

Cooling Water Leaving Temperature (
o
C)

Fan Type

Fan Outlet Size (m
2
)

Fan Volume (l/s)

Fan Drive

Motor Type

Motor Speed (rev/s)

Motor Rating (kW)

Tower Water Connections Diameter (mm)

Balance Pipe Connection Diameter (mm)

Supply Voltage (V)

4.5 Pumps ( Medium)

Location : No. : Design Test

Volume Flow Rate (l/s)

No Flow Head (kPa)

Full Flow Discharge Head (kPa)

Full Suction Pressure (kPa)

Full Flow Differential (kPa)

Motor Type

Motor Speed (rev/s)

Motor Full-load Condition (amp. & volt)

Supply Voltage (V)



Tested / Checked by Signature
(Name of Contractors Representative)

Witnessed by Signature(s)
(Name(s) of *PBSE/*PBSI))
Appendix A
Building Services Branch, ArchSD Page 11 of 14 Filecode: SR61.doc
FORM NO. BS/SR.061 Revision Date:15 March 2000
Issue Date: 3 March 2000

4.6 Air Handling Units

Location : No. : Design Test

Outdoor Air Condition

Dry Bulb Temperature (
o
C)

Wet Bulb Temperature (
o
C)

Time of Day (Hrs)

Condition (Cloudy/Sunny)

Total Air Quantity (l/s)

Fresh Air Quantity (Minimum) (l/s)

Fresh Air Quantity (Maximum) (l/s)

Fan

Type

Speed (r/s)

Drive

Inlet pressure (kPa)

Discharge pressure (kPa)

Fan Static Pressure (kPa)
(Discharge - Inlet)

Supply Voltage (V)

Filter

Type :

Inlet Pressure (kPa)

Outlet Pressure (kPa)









Tested / Checked by Signature
(Name of Contractors Representative)

Witnessed by Signature(s)
(Name(s) of *PBSE/*PBSI))
Appendix A
Building Services Branch, ArchSD Page 12 of 14 Filecode: SR61.doc
FORM NO. BS/SR.061 Revision Date:15 March 2000
Issue Date: 3 March 2000
Location : No. : Design Test

Effective Area (m
2
)

Velocity (m/s)

Cleanliness

Cooling Coil

Entering Air Dry Bulb Temperature (
o
C)

Entering Air Wet Bulb Temperature (
o
C)

Leaving Air Dry Bulb Temperature (
o
C)

Leaving Air Wet Bulb Temperature (
o
C)

Entering Water Temperature (
o
C)

Leaving Water Temperature (
o
C)

Entering Water Pressure (kPa)

Leaving Water Pressure (kPa)

Water Quantity (l/s)

Evaporator Suction Pressure (kPa)

Evaporator Suction Temperature (
o
C)

Evaporator Discharge Pressure (kPa)

Evaporator Discharge Temperature (
o
C)

Effective Area (m
2
)

Velocity (m/s)

Heating Coil (Medium)

Entering Air Dry Bulb Temperature (
o
C)

Leaving Air Dry Bulb Temperature (
o
C)

Effective Area (m
2
)

Velocity (m/s)

Entering Water Temperature (
o
C)

Leaving Water Temperature (
o
C)



Tested / Checked by Signature
(Name of Contractors Representative)

Witnessed by Signature(s)
(Name(s) of *PBSE/*PBSI))
Appendix A
Building Services Branch, ArchSD Page 13 of 14 Filecode: SR61.doc
FORM NO. BS/SR.061 Revision Date:15 March 2000
Issue Date: 3 March 2000
Location : No. : Design Test

Entering Water Pressure (kPa)

Leaving Water Pressure (kPa)

Water Quantity (l/s)

No. of steps

Capacity of Each Steps (kW)

Air Quantity (l/s)

4.7 Heating Coils (Not included in Air Handling Unit)

Location : No. : Design Test

Medium

Entering Air Dry Bulb Temperature (
o
C)

Leaving Air Dry Bulb Temperature (
o
C)

Effective Area (m
2
)

Velocity (m/s)

Air Quantity (l/s)

Entering Water Pressure (kPa)

Leaving Water Pressure (kPa)

Water Quantity (l/s)

Capacity of Coil (kW)

No. of Steps

Capacity of Each Step (kW)


4.8 Ducts, Grilles, Diffusers etc.

Use the air flow sheets and indicate the design and test figures as indicated in Fig. 5 Appendix
C.







Tested / Checked by Signature
(Name of Contractors Representative)

Witnessed by Signature(s)
(Name(s) of *PBSE/*PBSI))
Appendix A
Building Services Branch, ArchSD Page 14 of 14 Filecode: SR61.doc
FORM NO. BS/SR.061 Revision Date:15 March 2000
Issue Date: 3 March 2000

4.9 Testing Equipment

Type Model Serial No. of
Instrument
Date of
Calibration



































Note: * Delete if not applicable



Tested / Checked by Signature
(Name of Contractors Representative)

Witnessed by Signature(s)
(Name(s) of *PBSE/*PBSI))
Appendix B
Building Services Branch, Arch SD Page 1 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and commissioning progress chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Contract No. :

Contract Title :

Name of Contractor/sub-contractor :

Contract Period : / /20 to / /20 * Revised/Actual Completion Date : / /20

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
1. Chillers
1.1 Cleanliness &
State Check
Section
4.6.3.1.1

1.1.1 Air System Section
4.6.3.1.2.b

1.1.2 Water System Section
4.6.3.1.2.a

1.1.3 Refrig. System Section
4.6.3.1.2.c


Submission of
Record of Test


1.2 Mechanical Check Section
4.6.3.1.3

1.2.1 Fans Section
4.6.3.1.3.a

1.2.2 Pumps


1.2.3 Compressors Section
4.6.3.1.3.b

1.2.4 Drives Section
4.6.3.1.3c


Submission of
Record of Test


1.3 Electrical Check Section
4.6.3.1.4.

1.3.1 Electrical Supplies
Isolated
Section
4.6.3.1.4.a


Appendix B
Building Services Branch, Arch SD Page 2 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and commissioning progress chart
Air-conditioning, Refrigeration, Ventilation and Control Systems


Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
1.3.2 Electrical Supplies
Available
Section
4.6.3.1.4.b


Submission of
Record of Test


1.4 Test of Recip.
Compressor System
Section
4.6.3.2.

1.4.1 Pressure & Leakage
Test
Section
4.6.3.2.1

1.4.2 Evacuation &
Dehydration
Section
4.6.3.2.2

1.4.3 Charging of
Refrigerant
Section
4.6.3.2.4

1.4.4 Setting to Work &
Adjusting
Section
4.6.3.2.5.


Submission of
Record of Test


1.5 Test of Centrifugal
Compressor System
Section
4.6.3.3

1.5.1 Pressure & Leakage
Test
Section
4.6.3.3.1

1.5.2 Evacuation &
Dehydration
Section
4.6.3.3.2

1.5.3 Charging of
Refrigerant
Section
4.6.3.3.4

1.5.4 Setting to Work &
Adjusting
Section
4.6.3.3.5


Submission of
Record of Test


1.6 Test of Screw
Compressor System
Section
4.6.3.5

1.6.1 Pressure & Leakage
Test
Section
4.6.3.5.1

1.6.2 Evacuation &
Dehydration
Section
4.6.3.5.2



Appendix B
Building Services Branch, Arch SD Page 3 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)




Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
1.6.3 Charging of
Refrigerant
Section
4.6.3.5.4
All
refri.
1.6.4 Setting to Work &
Adjusting
Section
4.6.3.5.5


Submission of
Record of Test


1.7 Testing of
Absorption Chillers
Section
4.6.3.4.

1.7.1 General Check of
System Components
Section
4.6.3.4.

1.7.2 Leak Test of
Absorption Shell and
Purge Unit
Section
4.6.3.4.1

1.7.3 Evacuation of
Absorption System
Section
4.6.3.4.2

1.7.4 Charging of
Refrigerant
Section
4.6.3.4.4.

1.7.5 Setting to Work &
Adjusting
Section
4.6.3.4.5


Submission of
Record of Test


1.8 Functional Test for
Air & Water Cooled
Chillers
Section
4.6.3 &
Part 4
Setting
to
work
&
record
1.8.1 Chilled Water
Leaving
Temperature

1.8.2 Chilled Water
Entering
Temperature

1.8.3 Chilled Water Flow
Rate

1.8.4 Condenser Entering
Temperature (Water
Cooled Chillers)

1.8.5 Condenser Leaving
Temperature (Water
Cooled Chillers)


Appendix B
Building Services Branch, Arch SD Page 4 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
1.8.6 Compressor Motor
Speed

1.8.7 Compressor Running
Current

1.8.8 Air Flow Rate (Air
Cooled Chillers)

1.8.9 Fan Speed (Air
Cooled Chillers)

1.8.10
Fan Motor Speed
(Air Cooled Chillers)

1.8.11
Fan Motor Running
Current

1.8.12
Supply Voltage

Submission of
Record of Test


1.9 Functional Test for
Air Absorption
Chillers
Section
4.6.3 &
Part 4
Setting
to
work
&
record

Submission of
Record of Test


2. Chilled Water
System

2.1 Cleanliness & State
Check
Section
4.5.1.1

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test





Appendix B
Building Services Branch, Arch SD Page 5 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
"Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
2.2 Mechanical Check Section
4.5.1.4

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


2.3 General Checking Section
4.5.1.3

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


2.4 Electrical Check
(Pumps)
Section
4.5.1.6

2.4.1 Electrical Supply
Isolated
Section
4.5.1.6.1

Prim.
Sec.

Submission of
Record of Test


2.4.2 Electrical Supply
Available
Section
4.5.1.6.2

Prim.
Sec.







Appendix B
Building Services Branch, Arch SD Page 6 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
Submission of
Record of Test


2.5 Initial Running of
Pump Sets
Section
4.6.1.4

2.5.1 Pump Discharge
Rate
Section
4.6.1.4.

Prim.
Sec.

Submission of
Record of Test


2.5.2 Pump Suction
Pressure
Section
4.6.1.4.

Prim
Sec.

Submission of
Record of Test


2.5.3 Pump discharge
Pressure
Section
4.6.1.4

Prim
Sec.

Submission of
Record of Test


2.5.4 Pump Motor Speed Section
4.6.1.4.

Prim
Sec.









Appendix B
Building Services Branch, Arch SD Page 7 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A

Submission of
Record of Test


2.5.5 Pump Motor Current Section
4.6.1.4.

Prim
Sec.

Submission of
Record of Test


2.5.6 Supply Voltage Section
4.6.1.4.

Prim
Sec.

Submission of
Record of Test


2.5.7 Non-return Valve
Operation
Section
4.6.1

Prim.
Sec.

Submission of
Record of Test


2.5.8 Isolation Valve
Operation
Section
4.6.1

Prim.
Sec.

Submission of
Record of Test






Appendix B
Building Services Branch, Arch SD Page 8 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
2.5.9 Flexible Joint Section
4.6.1


Sec.

Submission of
Record of Test


2.6 Chemical Treatment Section 4.6
2.6.1 Cleanliness & State
Check

2.6.2 Mechanical Check
2.6.3 Electrical Check
2.6.4 General Check
2.6.5 Initial Running of
Chemical Dosing
Pump


Submission of
Record of Test


3. Air Distribution
System

3.1 Cleanliness & State
Check
Section
4.5.2.1

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test










Appendix B
Building Services Branch, Arch SD Page 9 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
3.2 Fire & Smoke
System Check

3.2.1 Regulating Device Section
4.5.2.2

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.2.2 Visual Check on Air
Tightness
Section
4.5.2.3.

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.2.3 Leakage Test
G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.2.4 Mechanical Check
on Fans & Dampers
Section
4.5.2.4.

G/F
1/F
2/F



Appendix B
Building Services Branch, Arch SD Page 10 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
3/F
4/F

Submission of
Record of Test


3.2.5 Initial Running of
Fans & Dampers

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.2.6 Regulating of Air
Flow

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.2.7 Functional &
Performance Test
Section
4.6.5

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test





Appendix B
Building Services Branch, Arch SD Page 11 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
3.3 Fire Tripping &
Safety Cutout

3.3.1 Electrical Check Section
4.5.2.5

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.3.2 Functional &
Performance Test
Section
4.6.5.

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.4 Fire & Smoke
Dampers Check

3.4.1 Cleanliness & State
Check
Section
4.5.2.1

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test







Appendix B
Building Services Branch, Arch SD Page 12 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
3.4.2 Functional &
Performance Test
Section
4.6.5

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.4.3 Electrical Check Section
4.5.2.5.

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.5 Mechanical
Ventilation System
Check

3.5.1 Cleanliness & State
Check
Section
4.5.2.1.

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.5.2 Regulating Device Section
4.5.2.2

G/F



Appendix B
Building Services Branch, Arch SD Page 13 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.5.3 Visual Check on Air
Tightness
Section
4.5.2.3

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.5.4 Leakage Test
G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.5.5 Electrical Check Section
4.5.2.5.

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test




Appendix B
Building Services Branch, Arch SD Page 14 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
3.5.6 Mechanical Check of
Fans, Hydro Vent.,
etc.
Section
4.5.2.4.

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.5.7 Initial Running of
Fans
Section
4.6.2.4

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.5.8 Regulating of Flow Section
4.6.2.5.

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.5.9 Function &
Performance Test
Section
4.6.5.

G/F
1/F
2/F

Appendix B
Building Services Branch, Arch SD Page 15 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
3/F
4/F

Submission of
Record of Test


3.6 Check of
Conditioned Air
Distribution

3.6.1 Cleanliness & State
Check
Section
4.5.2.1

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.6.2 Regulating Device Section
4.5.2.2

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.6.3 Visual Check on Air
Tightness
Section
4.5.2.3.

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


Appendix B
Building Services Branch, Arch SD Page 16 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
3.6.4 Leakage Test
G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.6.5 Electrical Check Section
4.5.2.5.

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.6.6 Insulation Check
G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.6.7 Mechanical Check Section
4.5.2.4.

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


Appendix B
Building Services Branch, Arch SD Page 17 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
3.6.8 Initial Running of
Fans & All Moving
Parts
Section
4.6.2.4.

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.6.9 Regulating Air Flow Section
4.6.2.5.

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.6.10 Flow Balancing
G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.6.11
Functional &
Performance Test
Section
4.6.5

G/F
1/F
2/F




Appendix B
Building Services Branch, Arch SD Page 18 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
3/F
4/F

Submission of
Record of Test


3.7 Check of Control
System
Section
4.6.4.1.1

3.7.1 Visual Inspection
G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.7.2 Basic Function Test Section
4.6.4.1.2

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.7.3 Electrical Check Section
4.6.4.1.3. &
Section
4.6.4.3

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


Appendix B
Building Services Branch, Arch SD Page 19 of 19 Filecode: SR21.Doc
FORM NO. PBS/SR.021 KFL/WKY
Issue Date: 3 March 2000

Testing and Commissioning Progress Chart
Air-conditioning, Refrigeration, Ventilation and Control Systems

Testing and Commissioning Progress Chart for Air-conditioning, Refrigeration, Ventilation
and Control Systems (Rev. )
(1)

Dates
(2)





Remark
Activities Reference
to
Approved
T&C
Procedure
S A S A S A S A S A S A S A S A
3.8 Noise & Sound
Check
Section
4.6.6

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


3.9 Vibration Check Section
4.6.7

G/F
1/F
2/F
3/F
4/F

Submission of
Record of Test


4.0 Submission of T&C
Certificate













Notes
* Delete if not applicable
(1) Insert revision no.
(2) Insert additional columns as necessary
S - schedule % completion
A - actual % completion
Appendix C
Page 1 of 5


Flow Chart for Testing and Commissioning Procedure
on
Air-conditioning, Refrigeration, Ventilation and Control Systems




Appendix C
Page 2 of 5




Figure 1. Example of Water Distribution System


Appendix C
Page 3 of 5




Figure 2. Example of Air Distribution System




Figure 3. Example of Air Distribution Branch












Appendix C
Page 4 of 5




Figure 4. Example of Low Velocity Supply Air System

Appendix C
Page 5 of 5



Figure 5. Example of Air Flow Sheet